CN1818106A - Porous and hollow sintered spongy structure of polyurethane and metal, and forming method thereof - Google Patents
Porous and hollow sintered spongy structure of polyurethane and metal, and forming method thereof Download PDFInfo
- Publication number
- CN1818106A CN1818106A CNA2005100033824A CN200510003382A CN1818106A CN 1818106 A CN1818106 A CN 1818106A CN A2005100033824 A CNA2005100033824 A CN A2005100033824A CN 200510003382 A CN200510003382 A CN 200510003382A CN 1818106 A CN1818106 A CN 1818106A
- Authority
- CN
- China
- Prior art keywords
- metal
- hollow
- polyurethane sponge
- metal structure
- porous
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 229910052751 metal Inorganic materials 0.000 title claims abstract description 83
- 239000002184 metal Substances 0.000 title claims abstract description 83
- 239000004814 polyurethane Substances 0.000 title claims abstract description 48
- 229920002635 polyurethane Polymers 0.000 title claims abstract description 48
- 238000000034 method Methods 0.000 title claims abstract description 35
- 239000000758 substrate Substances 0.000 claims abstract description 26
- 230000008569 process Effects 0.000 claims abstract description 13
- 239000011148 porous material Substances 0.000 claims abstract description 6
- 239000000463 material Substances 0.000 claims description 26
- 238000000576 coating method Methods 0.000 claims description 21
- 239000007769 metal material Substances 0.000 claims description 20
- 230000003197 catalytic effect Effects 0.000 claims description 15
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 14
- 239000011248 coating agent Substances 0.000 claims description 13
- 238000004519 manufacturing process Methods 0.000 claims description 13
- 238000005245 sintering Methods 0.000 claims description 13
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 claims description 7
- 229910052759 nickel Inorganic materials 0.000 claims description 7
- 239000001257 hydrogen Substances 0.000 claims description 6
- 229910052739 hydrogen Inorganic materials 0.000 claims description 6
- 229910045601 alloy Inorganic materials 0.000 claims description 5
- 239000000956 alloy Substances 0.000 claims description 5
- 238000010438 heat treatment Methods 0.000 claims description 5
- 238000007747 plating Methods 0.000 claims description 5
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 4
- 229910052802 copper Inorganic materials 0.000 claims description 4
- 239000010949 copper Substances 0.000 claims description 4
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 3
- 229910052782 aluminium Inorganic materials 0.000 claims description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 3
- 229910052804 chromium Inorganic materials 0.000 claims description 3
- 239000011651 chromium Substances 0.000 claims description 3
- 230000005611 electricity Effects 0.000 claims description 3
- 238000009713 electroplating Methods 0.000 claims description 3
- 239000007788 liquid Substances 0.000 claims description 3
- 239000000126 substance Substances 0.000 claims description 3
- 150000001722 carbon compounds Chemical class 0.000 claims description 2
- 230000008602 contraction Effects 0.000 claims description 2
- 238000004070 electrodeposition Methods 0.000 claims description 2
- 230000009467 reduction Effects 0.000 claims description 2
- 230000002787 reinforcement Effects 0.000 claims description 2
- 238000005507 spraying Methods 0.000 claims description 2
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims description 2
- 229910052721 tungsten Inorganic materials 0.000 claims description 2
- 239000010937 tungsten Substances 0.000 claims description 2
- 230000000845 anti-microbial effect Effects 0.000 claims 1
- 210000003850 cellular structure Anatomy 0.000 claims 1
- 238000001035 drying Methods 0.000 claims 1
- 230000033116 oxidation-reduction process Effects 0.000 claims 1
- 238000004140 cleaning Methods 0.000 abstract description 3
- 238000005422 blasting Methods 0.000 abstract 1
- 239000003054 catalyst Substances 0.000 description 14
- 239000000919 ceramic Substances 0.000 description 13
- MWUXSHHQAYIFBG-UHFFFAOYSA-N Nitric oxide Chemical compound O=[N] MWUXSHHQAYIFBG-UHFFFAOYSA-N 0.000 description 12
- 230000035939 shock Effects 0.000 description 10
- 239000000428 dust Substances 0.000 description 8
- 239000007789 gas Substances 0.000 description 6
- 230000008901 benefit Effects 0.000 description 5
- 239000000446 fuel Substances 0.000 description 5
- 239000000203 mixture Substances 0.000 description 5
- 239000011941 photocatalyst Substances 0.000 description 5
- 239000006260 foam Substances 0.000 description 4
- 238000001914 filtration Methods 0.000 description 3
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 2
- RAHZWNYVWXNFOC-UHFFFAOYSA-N Sulphur dioxide Chemical compound O=S=O RAHZWNYVWXNFOC-UHFFFAOYSA-N 0.000 description 2
- 210000004027 cell Anatomy 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 238000002485 combustion reaction Methods 0.000 description 2
- OMZSGWSJDCOLKM-UHFFFAOYSA-N copper(II) sulfide Chemical compound [S-2].[Cu+2] OMZSGWSJDCOLKM-UHFFFAOYSA-N 0.000 description 2
- 210000000497 foam cell Anatomy 0.000 description 2
- 239000011888 foil Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 230000003647 oxidation Effects 0.000 description 2
- 238000007254 oxidation reaction Methods 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 229910052709 silver Inorganic materials 0.000 description 2
- 239000004332 silver Substances 0.000 description 2
- 238000012546 transfer Methods 0.000 description 2
- 238000011282 treatment Methods 0.000 description 2
- 238000003466 welding Methods 0.000 description 2
- MGWGWNFMUOTEHG-UHFFFAOYSA-N 4-(3,5-dimethylphenyl)-1,3-thiazol-2-amine Chemical compound CC1=CC(C)=CC(C=2N=C(N)SC=2)=C1 MGWGWNFMUOTEHG-UHFFFAOYSA-N 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 229910021536 Zeolite Inorganic materials 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 239000000809 air pollutant Substances 0.000 description 1
- 231100001243 air pollutant Toxicity 0.000 description 1
- 230000000844 anti-bacterial effect Effects 0.000 description 1
- 239000006229 carbon black Substances 0.000 description 1
- 239000000969 carrier Substances 0.000 description 1
- 239000012876 carrier material Substances 0.000 description 1
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000001351 cycling effect Effects 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 239000002283 diesel fuel Substances 0.000 description 1
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 1
- 230000009977 dual effect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000010891 electric arc Methods 0.000 description 1
- 238000007772 electroless plating Methods 0.000 description 1
- 229920006332 epoxy adhesive Polymers 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- TUJKJAMUKRIRHC-UHFFFAOYSA-N hydroxyl Chemical compound [OH] TUJKJAMUKRIRHC-UHFFFAOYSA-N 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 230000001678 irradiating effect Effects 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 150000002736 metal compounds Chemical class 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000005555 metalworking Methods 0.000 description 1
- 239000002808 molecular sieve Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 229910000623 nickel–chromium alloy Inorganic materials 0.000 description 1
- JCXJVPUVTGWSNB-UHFFFAOYSA-N nitrogen dioxide Inorganic materials O=[N]=O JCXJVPUVTGWSNB-UHFFFAOYSA-N 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- 229910052697 platinum Inorganic materials 0.000 description 1
- 231100000572 poisoning Toxicity 0.000 description 1
- 230000000607 poisoning effect Effects 0.000 description 1
- 238000010791 quenching Methods 0.000 description 1
- 230000009257 reactivity Effects 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 239000002002 slurry Substances 0.000 description 1
- URGAHOPLAPQHLN-UHFFFAOYSA-N sodium aluminosilicate Chemical compound [Na+].[Al+3].[O-][Si]([O-])=O.[O-][Si]([O-])=O URGAHOPLAPQHLN-UHFFFAOYSA-N 0.000 description 1
- 238000001179 sorption measurement Methods 0.000 description 1
- 239000002993 sponge (artificial) Substances 0.000 description 1
- 150000004763 sulfides Chemical class 0.000 description 1
- 230000008719 thickening Effects 0.000 description 1
- 238000009423 ventilation Methods 0.000 description 1
- 239000011800 void material Substances 0.000 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
- 239000010457 zeolite Substances 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
- B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
- B01D46/2418—Honeycomb filters
Landscapes
- Physics & Mathematics (AREA)
- Geometry (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Catalysts (AREA)
Abstract
The invention opened a multihole hollow polyurethane spongy metal structure by nodulizing. It includes a blasting hole polyurethane spongy frame which has some hollows and some geometry semi/obturator foramens or semiopen pore. The out of the hollow geometric body has the super three-dimensional specific area. The process is: forming the multihole substrate, cover it with the metal and nodulize it; connect the body by the metallic bond and the covalent bond and indicate the hollow structure. So it can be used for the air cleaning filter carrier.
Description
Technical Field
The present invention relates to a sintered porous hollow polyurethane sponge metal structure and a method for producing the same.
Background
Generally, an air cleaning filter (also called a catalytic converter) in an exhaust system of a vehicle engine adopts a metal honeycomb structure, and exhaust gas in the exhaust system can be conveyed from one end to the other end of a channel in the honeycomb structure by adopting the honeycomb structure, so that the aim of treating various harmful gases such as nitric oxide, nitrogen dioxide and the like generated after oil is combusted is fulfilled.
US patent US5,306,890 discloses such a honeycomb structure. In this configuration, a corrugated metal sheet is welded between two flat metal sheets to form a plurality of channel structures. The formed channel structure is wrapped, coated with a catalyst, and mounted in a metal housing to form a catalytic converter. The corrugated structure in the catalytic converter has large contact surface area, so that the catalyst coated on the surface of the corrugated structure can filter air. However, this technique has the disadvantage that the welding process is expensive and the metal working of the surface area of the channel structure is limited by the state of the art.
In order to overcome the above-mentioned drawbacks of the prior art, US5,481,084 proposes a method of treating the surface of a metal foil with an electric arc to increase the surface area; US5,567,395 discloses a method of providing turbulence generating sections within a honeycomb structure to improve efficiency; US6,036,926 and WO97/15393 disclose a method of using bent reinforcing metal sheets to form a honeycomb structure with a reinforced structure and to improve efficiency. However, the above method still has a limited extent to increase the contact surface area. And after several thermal shock cycles, the problems of insufficient adhesion and insufficient durability of the metal surface often arise from the additional relief structure added by treating the surface to increase surface area.
It is then envisaged to install a fine filter (or "dust trap") (US4,719,571) before the honeycomb converter or parallel to the converter to mechanically control the flow of exhaust gas through selected chambers to trap dust (US5,264,186). It can prevent the catalyst poisoning caused by the dust and reduce the dust emission. However, the process is complicated and requires the installation of an additional filter unit, which increases the cost and weight of the vehicle.
The converter is heated when the engine is started and is turned off when the engine is stopped. Such repeated cycling often causes thermal shock to the transducer structure, causing the foil to break and form holes therein, thereby reducing or even failing the transducer's efficacy. This can of course be overcome by some means, such as improving the strength by special welding (US5,316,997), or by providing a buffer to protect the transducer from damage due to thermal shock (US5,403,558, US6,467,169, US6,458,329, US5,846,459). But this would allow the buffer zone to occupy more space, thereby reducing the surface area actually available to the transducer. And doing so also increases the overall volume of the converter. If the diameter of the converter is increased, the exhaust gas will pass through all the channels uniformly and the filtering effect will be reduced. If the length of the converter is increased, the back pressure to the engine will increase.
When the engine and converter have not reached their operating temperature, 90% of the current air pollutants are from vehicle exhaust emissions. For this reason, several solutions have been envisaged: for example, zeolite or molecular sieve adsorption chambers with a sparse micro-void structure (US5,051,224, US5,108,716) or separate preheating devices (US5,296,198, US5,465,573, etc.) for making the catalytic converter more efficient are used. However, such devices either increase back pressure, decrease fuel efficiency, or increase fuel consumption.
In addition to metal catalytic converters, a catalyst-coated compressed ceramic converter is used in US4,556,543. US6,680,101 suggests extrusion or press molding techniques to form a ceramic honeycomb structure having 400 channels per square inch.
However, such ceramic converters have poor thermal shock resistance, which can result in ceramic fracture and loss of performance after only a limited number of heat/quench cycles. Although several methods have been suggested to overcome this drawback. Such as by thickening the walls of certain channels to enhance thermal shock resistance (US 2004/0101654). However, these methods still do not satisfy the demand for effective catalyst carriers with lower weight.
Due to the low thermal capacity and thermal conductivity of ceramics, ceramic honeycomb structures take a long time to reach their operating temperature after engine start-up. When the temperature of the engine/converter is below its operating temperature, an additional filter or another preheater may be required to treat the exhaust gas. This not only increases cost and weight, but also reduces the fuel efficiency of the vehicle.
A third typical prior art is a ceramic foam structure as disclosed in US4,451,441. It involves using a fine ceramic foam cell (15 to 50ppi pores/inch) as the filter and a coarse ceramic foam cell (2 to 20ppi) as the catalyst support for the catalytic converter system. It has been proposed to provide a lightweight, large surface area, and much lower backpressure solution for catalyst applications. Ceramic foams are formed by coating ceramic slurry onto a reticulated polyurethane sponge followed by sintering at about 750 ℃. In fact, the polyurethane polymer is burned out during said sintering. However, since the skeleton of the ceramic foam is extremely small and thus has a small mechanical strength, it is impossible to transfer heat and impact during the lifetime and to provide sufficient strength.
A method for reducing the emission of nitrogen oxides (NOx) from the exhaust of a diesel engine is disclosed in US5,422,085. A silver catalyst was coated on a nickel-coated polyurethane sponge (also known as nickel foam in the chinese market) to treat the NOx loaded stream. However, such devices have not been commercially practical due to the high reactivity of silver with sulfides in the engine exhaust environment and the insufficient corrosion and oxidation resistance of nickel in oxidizing environments.
Precision machining tools are required for forming during the manufacturing of ceramic honeycomb structures. While the process tool has its life cycle and maintenance period. Also, ceramic materials need good protection in transport against impact damage. Therefore, the production cost is high and a new structure for the catalytic converter is required.
The present invention overcomes all of the above-described deficiencies in the prior art. It has the advantages of large area catalyst efficiency, effective filtering of diesel oil dust (particles), thermal shock resistance, short heating time and the like, and is low in production cost.
Disclosure of Invention
The main object of the present invention is to provide a sintered porous hollow polyurethane sponge metal structure and a method for producing the same.
The inventors used a combustible material, a burst open-cell polyurethane sponge as the porous substrate to coat the metal layer, and employed a sintering process to form a sintered porous hollow polyurethane sponge metal structure. So that the user can use the sintered porous hollow polyurethane sponge metal structure for catalyst coating or photocatalyst coating.
The invention provides a sintered porous hollow polyurethane sponge metal structure, which comprises a reduced metal dodecahedron framework structure, wherein a closed-cell, semi-closed-cell or semi-open-cell structure which is hollow and rigid and has a certain geometric shape is arranged in the framework, and the inner part and the outer part of the hollow geometric body have overlarge three-dimensional specific surface areas. The structure is internally provided with metal bonds or covalent bonds to connect the whole, and the material of the porous hollow structure can bear a sintering process with a specific temperature range; wherein at least half of the material of the porous hollow structure is formed of a metallic material.
The method of the invention comprises the following steps: forming a porous substrate from a combustible material; performing a coating process by a metal material that can withstand a combustion temperature of a combustible material; the coated porous substrate is subjected to a sintering process to remove the fugitive substrate, forming a monolithic structure due to the metallic material forming metallic or covalent bonds within the structure, thereby producing a sintered porous hollow polyurethane sponge metal structure having a porous hollow structure.
The structure of the present invention can be used as a dust filter and catalytic converter to treat exhaust gas from an engine by coating with a layer of catalytic material such as platinum. Also, the sintered porous hollow polyurethane sponge metal structure may be used as a cleaning filter in exhaust and intake systems by coating a layer of a material such as a photocatalyst.
Drawings
The objectives and other features and advantages of the present invention will become apparent to the reader upon reading the following detailed description of the invention, when taken in conjunction with the accompanying drawings. Wherein,
FIG. 1 is a flow chart of a method of making a sintered porous hollow polyurethane sponge metal structure according to the present invention;
FIG. 2 is a view of one form of cavities within a sintered porous hollow polyurethane sponge metal structure of the invention;
FIG. 3 shows a part of the skeleton of the porous hollow polyurethane sponge metal structure of the present invention.
Detailed Description
The present invention provides a method of making a sponge metal structure having high tensile strength, large surface area with low back pressure, low coefficient of thermal expansion, high thermal shock resistance, light weight and design flexibility to provide preheating of the metal sponge structure to reduce complexity and effectively improve fuel to meet the needs in catalytic converter applications. At the same time, the surface area is increased to provide more efficient exhaust treatment while reducing the weight of the converter.
The exploded open-cell polyurethane sponge material (or similar polymer structure) is first treated by electrochemical deposition. To ensure conductivity, the surface of the polyurethane sponge was pre-coated with a conductive layer of copper sulfide (94% by weight copper sulfide and 6% by weight epoxy adhesive). Other conductive layers are also possible, for example, graphite, carbon black, etc. may also be used. Other methods for providing a conductive layer on a polyurethane substrate may also be used, such as PVD, CVD, electroless plating, and the like. The resulting polyurethane sponge material is then electroplated with any desired metal or specific metal composition. The latter can be achieved by adjusting the electrode and electroplating bath composition (bath composition). After a specific thickness of metal (typically from 60 to 150 microns) is applied on top of the polyurethane sponge structure and on the conductive layer, the coated porous substrate is maintained in the range of 260-270 ℃ to vaporize the flame resistant substrate, thereby removing the substrate. The resulting metal sponge skeleton is then sintered in a reducing furnace at 350 ℃ to 500 ℃ in a hydrogen atmosphere for 30 to 45 minutes, and the temperature is then gradually raised to 650 ℃ to 900 ℃ in about 30 minutes. The porous hollow spongy metal structure can be reduced by a hydrogen atmosphere in a reducing furnace at 650 ℃ to 900 ℃ for an additional 60 to 90 minutes. The sintering temperature needs to be carefully controlled so as not to melt the metal composition, but the metal compound needs to be reduced, leaving hollow cavities of a certain geometry covered by the metal. The geometry shown in fig. 2 is triangular, but in practice the geometry of the hollow cavity can be any geometry that can be achieved, as will be appreciated by those skilled in the art. The cavity has the characteristics of expansion with heat and contraction with cold, and the thermal expansion of the whole structure can be reduced.
The resulting metal sponge may then be coated with the catalyst composition by previous coating techniques for catalytic converters. The resulting sponge-like metal structure is an ideal carrier body and can be used not only as a carrier for these catalysts but also as a diesel dust trap (or referred to as "filter") having a fine unit structure (90 to 120 ppi). The cell structure is limited only by the initially burst open-celled polyurethane sponge morphology. Thus, cell sizes from 5 to 150ppi can be formed.
The voids under the metal struts provide the metal sponge with excellent strength and thermal shock resistance. Due to the shape of the metal walls, the sponge-like metal structure has a very low linear thermal expansion, which provides good dimensional and thermal shock stability. The voids also allow for weight reduction of the material with maximum surface area. The reduction in weight makes it possible to heat the metal sponge structure with less heat, so that the catalytic converter made of the metal sponge structure can be heated to the operating temperature more quickly.
Another benefit of the present invention is that the metal sponge may be coated on the outer surface of the skeleton using a nickel-chromium alloy. It can then be heated using a suitable current from the car generator or battery. It provides a pre-heated carrier which can be used to replace any carrier material of the prior art for catalytic converters or filters/traps. This not only simplifies the current requirement for having dual chambers, but also improves fuel efficiency while reducing manufacturing costs.
FIG. 1 is a flow chart of a method for producing a sintered porous hollow polyurethane sponge metal structure. The sintered porous hollow polyurethane sponge metal structure can be widely used in a liquid transfer machine for certain treatments of chemical reactions. The manufacturing method comprises the following steps: forming the porous substrate from a combustible material, such as a polymer sponge; coating the prepared substrate with a metal material capable of withstanding the combustion temperature of the combustible material; the coated porous substrate is sintered to remove the combustible substrate and form an integral porous hollow structure by metallic or covalent bonds formed within the structure by the metallic material, thereby producing the sintered porous hollow polyurethane sponge metal structure of the invention. Among them, in metals or alloys thereof, metallic bonds can be easily regarded as covalent bonds, and the covalent bonds are used to improve little non-metallic material within the metal base resulting from sintering or for characteristic improvement of the metal base.
The steps of the invention may also include the following variations: wherein the coating process may comprise two sub-process steps for coating the metallic material onto the combustible material, a pre-coating process for adhering a layer of material that allows metal plating on the porous substrate, and a reinforcement coating process for plating a thicker layer of metallic material to construct the main porous structure of the sintered porous hollow polyurethane sponge metallic structure. Wherein the pre-coating process may sputter metal on the porous substrate or may allow for metal plating of the material. Wherein the pre-coating process may coat the porous substrate with a conductive paste. The coating method of the conductive adhesive is spraying. Wherein the pre-coating process may place the porous substrate portion in a specified chemical solution containing a material that allows for metal plating. Wherein the metallic material comprises nickel or chromium to enable the use of electricity to heat the porous structure for industrial applications (such as preheating in the exhaust pipe of a vehicle). Wherein the metal material comprises copper, aluminum or an alloy thereof. The metal used has flexibility of mounting and heat resistance of the sintering process. Wherein the sintering process may comprise a process that produces a metal deoxidation reaction in a pure hydrogen gas.
The structure of the sintered porous hollow polyurethane sponge metal structure comprises: a porous hollow structure having metallic or covalent bonds within the structure to connect the structure into a unitary body, and the material from which the porous hollow structure is made is capable of withstanding a sintering process having a temperature range (e.g., temperatures up to 2500 degrees celsius); wherein at least 90% or even the entirety of the material of the porous hollow structural body is formed of a metal material. The resulting porous hollow polyurethane sponge metal structure is shown in fig. 3. The sintered porous hollow polyurethane spongy metal structure formed by the process has an ultra-large three-dimensional specific surface area: 450m2/m3To 28000m2/m3. And the ratio of the volume of the skeleton of the structure to the volume of the porous polyurethane sponge metal structure is less than 3%.
Hereinafter, variations of the structure of the sintered porous hollow polyurethane sponge metal structure will be described: wherein the porous hollow structure has pores in the interior thereof, and residual carbon compounds generated by the sintering heating process are attached to the walls of the pores. Wherein the porous structure may be curved so that a specific spatial shape (such as ventilation ducts and exhaust ducts) may be formed in a specific flowing liquid device, which is adapted to the shape of the device. The specific temperature range may be up to 2500 degrees celsius. The porous hollow structure may be coated with a catalytic material or an antibacterial material. Metallic materials that may be used include copper, aluminum, tungsten or alloys thereof, and may also be nickel or chromium to enable the porous hollow structure to be heated by electricity for industrial applications.
The present invention has a number of significant benefits over the prior art. For example, it is a weldless structure, high catalyst efficiency due to a non-uniform porous hollow structure, effective diesel dust (particle) filtering property, thermal shock resistance, and short heating time, etc. Also, the production cost is reasonable for mass production.
In addition, the structure of the present invention can be used as a base structure to coat a photocatalyst material due to the characteristics of the sintered porous hollow polyurethane sponge metal structure having the above-described many benefits. The photocatalyst generates strong oxidation of hydroxyl radical under the condition of irradiating ultraviolet rays, and the porous hollow polyurethane spongy metal structure is not oxidized at present, so that the photocatalyst has wide market prospect.
At the same time, the field of application of the sintered porous hollow polyurethane sponge metal structures can be extended to the chemical industry, for example, for coating catalyst layers for nitrogen oxide (DeNOx) removal or sulfur dioxide (DeSO) removal2)。
The foregoing description of the preferred embodiments of the invention has been presented. It will be apparent to those skilled in the art that various modifications may be made to the above-described embodiments without departing from the scope of the invention as defined in the claims, and that such modifications are within the scope of what is set forth in the claims.
Claims (17)
1. A hollow polyurethane sponge metal structure, which is a sintered porous skeleton structure with reduced metal dodecahedron, characterized in that the skeleton has a hollow, rigid and geometrically closed, semi-closed or semi-open structure inside, and the hollow rigid geometric body has an ultra-large three-dimensional specific surface area inside and outside.
2. The hollow polyurethane sponge metal structure of claim 1, wherein said trisThe specific surface area is 450m2/m3To 28000m2/m3。
3. The hollow polyurethane sponge metal structure of claim 1, wherein the ratio of the skeletal volume to the volume of the hollow polyurethane sponge metal structure is less than 3%.
4. The hollow polyurethane sponge metal structure of claim 1, wherein said hollow geometric structure has thermal expansion and contraction characteristics.
5. The hollow polyurethane sponge metal structure of claim 1, wherein at least 90% of said structure is formed of a metallic material.
6. The hollow polyurethane sponge metal structure of claim 1, wherein said structure has pores therein, and wherein the walls of said pores have residual carbon compounds resulting from the sintering process.
7. The hollow polyurethane sponge metal structure of claim 1, wherein said structure is bendable to form a specific spatial shape suitable for use in a device for flowing a liquid.
8. The hollow polyurethane sponge metal structure of claim 1, wherein said structure is coated with a catalytic or antimicrobial material.
9. The hollow polyurethane sponge metal structure of claim 5, wherein said metallic material comprises copper, nickel, tungsten or alloys thereof.
10. A method of making a hollow polyurethane sponge metal structure according to claim 1, comprising the steps of:
(a) forming a porous substrate from a combustible material;
(b) coating the surface of the porous substrate with a flame-resistant metal material capable of bearing the temperature of more than 270 ℃;
(c) maintaining the coated porous substrate at a temperature in the range of 150 ℃ to 300 ℃ to vaporize a combustible substrate to remove the combustible substrate and to join the whole by metallic or covalent bonds in the structural surface metallic material coating through the metallic material to produce the porous hollow, rigid metallic structure;
(d) after the drying procedure, carrying out electrochemical deposition and electroplating on the same metal to increase the thickness of the porous hollow spongy metal structure;
(e) and (3) gradually heating the thickened porous hollow spongy metal structure in a hydrogen reduction furnace by pure hydrogen to perform oxidation reduction: sintering in a hydrogen atmosphere at a temperature in the range of 350 ℃ to 500 ℃ for 30 to 45 minutes; the temperature is then gradually raised to 650 ℃ to 900 ℃ over about 30 minutes, and the porous hollow spongy metal structure is subsequently reduced in a reducing furnace at 650 ℃ to 900 ℃ in a hydrogen atmosphere over a further 60 to 90 minutes.
11. The method of claim 10, wherein step (b) comprises the following two substeps:
(b1) a pre-coating sub-step for adhering a layer of material that can be metal plated on the porous substrate; and
(b2) a reinforcement coating substep for electroplating a thick layer of metallic material to construct the main cellular structure of the sintered polyurethane sponge metallic structure.
12. The method of claim 11, wherein said substep (b1) comprises employing a material that sputters metal or allows for metal plating on said porous substrate.
13. The method of claim 11, wherein said substep (b1) comprises applying a conductive paste on said porous substrate.
14. The method of claim 13, wherein the step of applying the conductive paste comprises spraying.
15. The method of claim 11, wherein said substep (b1) comprises subjecting said porous substrate to a specified chemical solution containing said metal electroplatable material.
16. The method of claim 10, wherein the metallic material comprises nickel or chromium to enable heating of the structure by electricity.
17. The method of claim 10, wherein the metallic material comprises copper, aluminum, or alloys thereof.
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CNA2005100033824A CN1818106A (en) | 2005-12-31 | 2005-12-31 | Porous and hollow sintered spongy structure of polyurethane and metal, and forming method thereof |
| PCT/CN2006/001371 WO2007076650A1 (en) | 2005-12-31 | 2006-06-16 | Sintered hollow polyurethane spongy metal structure and preparation method thereof |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CNA2005100033824A CN1818106A (en) | 2005-12-31 | 2005-12-31 | Porous and hollow sintered spongy structure of polyurethane and metal, and forming method thereof |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN1818106A true CN1818106A (en) | 2006-08-16 |
Family
ID=36918301
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CNA2005100033824A Pending CN1818106A (en) | 2005-12-31 | 2005-12-31 | Porous and hollow sintered spongy structure of polyurethane and metal, and forming method thereof |
Country Status (2)
| Country | Link |
|---|---|
| CN (1) | CN1818106A (en) |
| WO (1) | WO2007076650A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116024619A (en) * | 2022-11-25 | 2023-04-28 | 梧州三和新材料科技有限公司 | Porous metal with open framework and method of making same |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP3287206B1 (en) * | 2015-04-24 | 2023-08-16 | Sumitomo Electric Industries, Ltd. | Composite material and method for producing same |
| GB201813060D0 (en) * | 2018-08-10 | 2018-09-26 | Artios Pharma Ltd | Novel compounds |
| CN113136007A (en) * | 2021-03-26 | 2021-07-20 | 林轩 | Preparation method of porous ABS graft polymer particles easy to dry |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| KR100193356B1 (en) * | 1994-03-31 | 1999-06-15 | 이사오 우치가사키 | Method of producing a porous body |
| CN1040237C (en) * | 1995-03-11 | 1998-10-14 | 吉林大学 | Process for preparing spongy foam nickel |
| CN1172388C (en) * | 2002-01-24 | 2004-10-20 | 南开大学 | Foam-metal current collector of secondary battery using zinc as negative electrode and its preparing process |
-
2005
- 2005-12-31 CN CNA2005100033824A patent/CN1818106A/en active Pending
-
2006
- 2006-06-16 WO PCT/CN2006/001371 patent/WO2007076650A1/en active Application Filing
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116024619A (en) * | 2022-11-25 | 2023-04-28 | 梧州三和新材料科技有限公司 | Porous metal with open framework and method of making same |
Also Published As
| Publication number | Publication date |
|---|---|
| WO2007076650A1 (en) | 2007-07-12 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| EP1541216B1 (en) | Honeycomb structure body | |
| EP0684071A2 (en) | Electrically heatable activated carbon bodies for adsorption and desorption applications | |
| CA2347376A1 (en) | Corrugated wall honeycomb structure and production method thereof | |
| JP2008296212A (en) | Porous catalyst structure and method for producing the same | |
| CN1772383A (en) | Porous catalytic filtering metal material and its prepn | |
| EP2484424A1 (en) | Exhaust gas purification filter | |
| WO2006082684A1 (en) | Honeycomb structure | |
| WO2004076027A1 (en) | Ceramic honeycomb structure | |
| KR20020047154A (en) | Catalyst for the selective oxidation of carbon monoxide and its preparation | |
| KR20060022453A (en) | Apparatus for purifying diesel exhaust gas with coated photocatalyst layer and electrode, and manufacturing method thereof | |
| CN1818106A (en) | Porous and hollow sintered spongy structure of polyurethane and metal, and forming method thereof | |
| KR20190071305A (en) | Metal Structure based NOx Removal Catalyst for Selective Catalyst Reduction using Coating Slurry and Method for Manufacturing Same | |
| EP1510670B1 (en) | Exhaust gas-purifying apparatus | |
| JP3091246B2 (en) | Heat-resistant metallic monolith and method for producing the same | |
| Wang et al. | Stainless steel catalyst for air pollution control: structure, properties, and activity | |
| JP2021155276A (en) | Porous ceramic structure and manufacturing method of porous ceramic structure | |
| US20070098587A1 (en) | Sintered porous frame and its producing method | |
| CN1772382A (en) | Metal carrier for automobile tail gas purifier catalyst and its prepn | |
| US20040211172A1 (en) | Muffler and catalytic converter devices | |
| JP2010106735A (en) | Heating element, exhaust emission control device for internal combustion engine, and fuel reformer | |
| CN1966942A (en) | Spiral type filtering-regeneration device for particulates in exhaust gas from diesel vehicle | |
| JP2007021409A (en) | Method for manufacturing diesel particulate filter | |
| JP2007222853A (en) | Catalyst support and its manufacturing method | |
| EP1616083B1 (en) | Muffler and catalytic converter devices | |
| CN1116115C (en) | Catalytically active structure |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| C06 | Publication | ||
| PB01 | Publication | ||
| C10 | Entry into substantive examination | ||
| SE01 | Entry into force of request for substantive examination | ||
| REG | Reference to a national code |
Ref country code: HK Ref legal event code: DE Ref document number: 1094459 Country of ref document: HK |
|
| C02 | Deemed withdrawal of patent application after publication (patent law 2001) | ||
| WD01 | Invention patent application deemed withdrawn after publication | ||
| REG | Reference to a national code |
Ref country code: HK Ref legal event code: WD Ref document number: 1094459 Country of ref document: HK |