KR101506453B1 - Manufacturing process of foaming metal product and this using metal product - Google Patents

Abstract

The present invention relates to a method of manufacturing a foamed metal product and a foamed metal product using the foamed metal product, and more particularly, to a method of manufacturing a foamed aluminum product, a foamed alloy and a foamed ceramic product, And thus, there is no loss of material and productivity is improved, and a foamed metal product using the same.
The present invention relates to a method for manufacturing an aluminum alloy, comprising the steps of: pulverizing a raw material made of aluminum, aluminum scrap, or an alloy to form a powder; Stirring the raw material, the thickener, the foaming agent, and the coloring paint of the powder; Pressing the powder into a lump of a predetermined size; A component fixing step inside the forming mold; Injecting powder or lumps into the forming mold; Firing and melting the powder or lump to form the powder or lump according to the shape of the forming mold; Cooling the mold by air cooling or water cooling; and removing the mold.

Description

Technical Field [0001] The present invention relates to a method for manufacturing a foamed metal product,

The present invention relates to a method of manufacturing a foamed metal product and a foamed metal product using the foamed metal product, and more particularly, to a method of manufacturing a foamed aluminum product, a foamed alloy and a foamed ceramic product, And thus, there is no loss of material and productivity is improved, and a foamed metal product using the same.

Generally, a foamed metal is a porous metal having numerous bubbles inside the material, and is classified into an open cell type and a closed cell type. In the case of the alveolar-type foamed metal, bubbles in the metal are not connected but exist independently. In the case of the open-celled foamed metal, the pores in the material are connected to each other and the gas or fluid can pass easily. .

These porous metals are widely used in aircrafts, automobiles, power plants, heat exchangers for power devices, heat dissipation of semiconductors or various electronic products, silencers for large plants, catalysts for chemical plants, aircraft requiring high strength and light weight, It is used in various fields such as structural materials of space industry, shock absorber, fuel cell, filter, shock absorber, electromagnetic shielding, interior and exterior materials.

As the foamed metal which is the porous metal, foamed aluminum is generally used, and aluminum foamed metal contains innumerable bubbles in the inside. Since this foamed aluminum has a porosity of 90 to 95% or more in general, it has a specific gravity in the range of 0.2 to 1.0, is light in weight, and is a material excellent in sound absorption, soundproofness and shock absorbability due to the pores. Furthermore, since the raw material is aluminum, it is excellent in refractory heat resistance, rigidity and workability, and is widely used as a functional material.

In order for the aluminum foamed metal to have such characteristics, the shape and size of the pores present in the metal should be constant, and the productivity of the aluminum foamed metal should be improved.

[0008]

The above-mentioned patent document discloses a method for producing a high-strength aluminum alloy crucible, which comprises the steps of charging an aluminum ingot into a cylindrical crucible and then gradually adding the thickening agent and the foaming agent while stirring and melting the mixture to stir the mixture uniformly, A step of forming and growing bubbles of the foamed aluminum mold, and a step of cooling and post-processing the foamed mold, thereby producing a foamed aluminum metal solid body.

As the thickener to be added in the production of the aluminum foaming metal, 1-5 weight% of calcium is added to the molten aluminum in the range of 660-750 DEG C, and TiH2 is used as the foaming agent.

However, in the case of the above-mentioned blowing agent, there is a problem that it is a major factor of the increase in the production cost of the product because the efficiency of loss of about 95% is lost during manufacture and the loss of the raw material is increased.

Further, after the slide valve of the crucible is closed and aluminum molten metal is injected into the upper crucible, the thickener is introduced while the stirrer is operated. When the viscosity of the aluminum molten metal is increased over a certain time, the foaming agent is added. The slide valve is opened to drop the uniformly mixed molten metal into a lower mold heated to an appropriate temperature and cooled, thereby forming a desired foamed aluminum metal ingot. The thus formed foamed aluminum metal block is cut to a predetermined size and shipped.

However, in the case of producing the foamed aluminum metal by such a method, the molten metal is injected into the crucible and then the thickener and the foaming agent are sequentially added to the same crucible while stirring the aluminum molten metal, Uneven bubbles are generated when large-sized bubbles are formed in the upper layer portion or unfoamed portions are formed in the bottom portion when the aluminum metal block is made.

In the case of the foamed aluminum metal ingot, since only the arrangement type is formed, the foamed aluminum metal ingot is cut again according to the required specifications. However, this cutting operation is extremely difficult, and a large amount of powder of the foamed aluminum metal ingot is generated during cutting There was a problem of a large loss of raw materials.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and its object is to make available shapes and functions to meet the purpose of use. Conventionally, only the foamed aluminum is limited to various fields such as foamed metal, foamed alloy, , It is possible to easily produce the foamed product, thereby enhancing the productivity and function of the product.

In addition, the idea of melting the ingot in the existing crucible is to increase the efficiency of the production and the loss of the material by using various materials in the form of a powder, have.

According to an aspect of the present invention, there is provided a method of manufacturing a semiconductor device, comprising: grinding a raw material made of aluminum, aluminum scrap, or an alloy to form a powder; Stirring the raw material, the thickener, the foaming agent, and the coloring paint of the powder; Pressing the powder into a lump of a predetermined size; A component fixing step inside the forming mold; Injecting powder or lumps into the forming mold; Firing and melting the powder or lump to form the powder or lump according to the shape of the forming mold; Cooling the mold by air cooling or water cooling; and removing the mold.

In one embodiment, the raw material, the thickener, the foaming agent and the coloring paint are composed of 86 to 96% by weight of raw materials, 1 to 6% by weight of a thickener, 1 to 10% by weight of a foaming agent and 1 to 8% .

In one embodiment, the raw material further comprises a ceramic.

In one embodiment, the thickener is characterized in that any one or more of calcium, sodium, nitrogen, oxygen, carbon dioxide, water, and argon are mixed.

In one embodiment, the foaming agent is at least one of TiH2, ZrH2, polyvinyl alcohol, polyurethane, polyvinyl acetate, phenol resin, cellulose, sodium phosphate, sodium chloride, calcium chloride, sodium acetate, ferric chloride Are mixed.

In one embodiment, the colored paint is characterized in that any one or two or more of calcium hydroxide, zinc, silicon, carbon dioxide, ArH2, Na2, Co3, iron, cobalt, manganese, nickel and copper is mixed.

According to another aspect of the present invention, there is provided a method of manufacturing a semiconductor device, the method comprising: forming a metal foil, a bolt, a nut, a JIG, a rod, a plate, a pipe,

According to the method of manufacturing a foamed metal product of the present invention, first, a raw material, a thickener, a foaming agent, and a coloring paint are simultaneously injected into the inside of a molding die to form a foamed metal product, It is possible to obtain a high-quality foamed metal product and to prevent the loss of material.

Second, because the user forms a forming mold having a desired shape, there is no separate cutting and press working after the formation of the foamed metal, so that the workability is improved and the forming mold once formed can be continuously used, .

Thirdly, it is possible to selectively use raw materials, thickeners, foaming agents, and coloring paints according to the purpose of use, thereby enhancing the applicability and functionality of products.

Fourth, since the coloring paint is injected together with foaming when it is foamed, it is not necessary to perform coating work on the surface of the foamed metal separately, so that the operation is simplified.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a process drawing showing a process sequence of a method for manufacturing a foamed metal product of the present invention.
FIG. 2A is a view illustrating a method of manufacturing a foamed metal ingot through the method of manufacturing a foamed metal product according to the present invention.
FIG. 2B is a perspective view showing a foamed metal ingot formed by the method of FIG. 2A. FIG.
FIG. 2c is a view showing a state in which the foamed metal ingot of FIG. 2b is used in various directions.
3 is a cross-sectional view illustrating a method of manufacturing a foamed metal product of various shapes through a method of manufacturing a foamed metal product according to the present invention.
4A is a perspective view illustrating a method of manufacturing a condenser for cooling and heating through a method of manufacturing a foamed metal product according to the present invention.
4B is a perspective view illustrating a cooling / heating condenser manufactured by the manufacturing method of FIG. 4A.
FIG. 5A is a view showing a state in which a nut is included in a structure through a method of manufacturing a foamed metal product according to the present invention. FIG.
FIG. 5B is a view showing a state where a nut is integrally fastened to a structure by the manufacturing method of FIG. 5A.
6A is a view showing an inner wall of a building manufactured using the foamed metal product according to the present invention.
6B is a view showing a state in which the inner wall manufactured by the manufacturing method of FIG. 6A is fastened to the wall surface of the building.
7A is a perspective view showing a state where a door is manufactured using the foamed metal product according to the present invention.
FIG. 7B is a perspective view showing a door manufactured by the manufacturing method of FIG. 7A. FIG.

For a better understanding of the present invention, a preferred embodiment of the present invention will be described with reference to the accompanying drawings. The embodiments of the present invention may be modified into various forms, and the scope of the present invention should not be construed as being limited to the embodiments described in detail below. The present embodiments are provided to enable those skilled in the art to more fully understand the present invention. Therefore, the shapes and the like of the elements in the drawings can be exaggeratedly expressed to emphasize a clearer description. It should be noted that in the drawings, the same members are denoted by the same reference numerals. Further, detailed descriptions of well-known functions and configurations that may be unnecessarily obscured by the gist of the present invention are omitted.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a method of manufacturing a foamed metal product of the present invention will be described in detail with reference to the preferred embodiments of the present invention with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a process drawing showing a process sequence of a method for manufacturing a foamed metal product of the present invention.

Referring to FIG. 1, a method of manufacturing a foamed metal product according to the present invention comprises grinding a raw material composed of aluminum, an aluminum scrap material, or an alloy to form a powder (S10). Here, the raw material may further include a ceramic, so that a foamed product can be produced through various materials. The above-mentioned foamed ceramic is used for the interior and exterior materials of the building and for replacing wood. In addition, it is a non-toxic eco-friendly ceramic such as a catalyst and a filter.

Then, the raw material of the powder, the thickener, the foaming agent, and the coloring paint are stirred (S20). The thickener, the foaming agent, and the coloring paint may be used in the form of a powder or a predetermined size according to the purpose and function of the use and the user's needs.

On the other hand, it is preferable that the raw materials, the thickener, the foaming agent, and the coloring paint are mixed with 86 to 96% by weight of the raw materials, 1 to 6% by weight of the thickener powder, 1 to 10% by weight of the foaming agent and 1 to 8% . Depending on the kind of the raw material, the content of the thickener, the foaming agent, and the coloring paint described above may be changed.

The thickener may be composed of any one of calcium, sodium, nitrogen, oxygen, carbon dioxide, water, and argon. Two or more compositions may be included in the composition depending on the kind of the raw material and the intended use.

The blowing agent may be composed of any one of TiH2, ZrH2, polyvinyl alcohol, polyurethane, polyvinyl acetate, phenol resin, cellulose, sodium phosphate, sodium chloride, calcium chloride, sodium acetate and ferric chloride. Two or more compositions may be included in the composition depending on the kind of the raw material and the intended use.

The coloring paint may be composed of any one of calcium hydroxide, zinc, silicon, carbon dioxide, ArH2, Na2, Co3, iron, cobalt, manganese, nickel and copper. Two or more compositions may be included in the composition depending on the kind of the raw material and the intended use.

Thereafter, each of the compositions thus stirred is inserted into the mold 10 (S30). The mold frame 10 is composed of an upper housing 11 and a lower housing 12 and a rib is formed at the edge thereof to be tightened by the bolts 13 and the nuts 14 to be sealed. Although the upper and lower housings are shown in the figure, a single molding frame can be manufactured and used depending on the manufactured product. The foamed metal 20 and the plate 40 may be integrally formed when the plate 40 is attached to the inner wall of the mold 10 to foam the raw materials, the thickener, the foaming agent, and the coloring paint. .

Thereafter, the powder is pressed into a predetermined size (S30) to form a predetermined volume. Here, the stirring step (S20) and the compression step (S30) may be selectively performed according to the size of the raw material.

Then, the constituent is fixed to the inside of the mold 10 (S40). In this case, the construct may be formed directly on the inner surface of the forming die 10 at a negative or positive angle, and the bolt 60 or the nut 30 itself is fixed to the inner side of the forming die 10. In addition to the bolts or nuts, an IG, a rod, a plate, a pipe, a pipe, a fixing pin, and the like may be fixed.

Thereafter, the mixed powder or lump is injected into the mold 10 (S50).

Thereafter, the powder or lump is melted and molded according to the shape of the forming die 10 (S60). At this time, the melting temperature is preferably 600 to 800 degrees in the case of aluminum or an alloy, and 1000 to 1200 degrees in the case of a metal or a ceramic. Accordingly, the powder or lump is melted and bulges to fill the forming die 10. At this time, the bolts 60, the nuts 30 and the like are fixed to the inside of the foamed metal 20 to be integrally formed with the foamed metal 20.

Thereafter, when the foaming is completed, the forming die 10 is cooled by air or water (S70).

Finally, the mold 10 is removed (S80) to obtain a necessary product.

Since each product such as a metal block, bolt, and nut inserted in this manner can be shipped through only a slight trimming process after the forming frame 10 is removed and then cooled by air cooling or water cooling, waste of raw materials So that the economical efficiency is increased, and the convenience of the work and the efficiency are increased. Further, since the mold is manufactured through the mold, the safety of the operator is secured.

Hereinafter, a method for manufacturing various types of foamed metal products through the method of manufacturing a foamed metal product will be described.

FIG. 2B is a perspective view illustrating a foamed metal ingot formed by the method of FIG. 2A, FIG. 2C is a perspective view of the foamed metal ingot formed by the method of FIG. Fig. 5 is a view showing a state in which foamed metal ingots are used in various directions.

The embodiment of Fig. 2 shows the production of a metal ingot. As shown in Fig. 2A, a molding material 10 composed of an upper housing 11 and a lower housing 12 is filled with a raw material, a thickener, a foaming agent, And then fired or melted in the mold 10 for a predetermined time, the respective compositions are swelled by the foaming agent to produce the foamed metal mass 20 as shown in FIG. 2B.

The foamed metal mass produced as described above can be used as a metal mass itself. As shown in FIG. 2C, it is possible to cut each part and use it. For example, a relatively large area such as a planar portion and a bottom portion can be used for a wall of a building or the like, and the foamed metal 20 formed on the inside can be used for a fire wall which is one of interior materials, sound absorbing materials or military facilities of a building. For example, when a shell is exploded in a barrier wall, a general steel plate is torn. In the case of the foamed metal 20, since the pores are formed on the surface, the inside of the barrier can be safely protected will be.

3 is a cross-sectional view illustrating a method of manufacturing a foamed metal product of various shapes through a method of manufacturing a foamed metal product according to the present invention.

The embodiment of Fig. 3 is identical to the embodiment of Fig. 2 described above and the method of manufacturing a foamed metal product. However, the shapes of the upper and lower housings 11 and 12 are different from each other, and a shape corresponding to the intention of the user is formed on the inner side with the embossed or engraved. When the powder or lump of the raw material, the thickener, the foaming agent, and the coloring paint is then injected and fired or melted in the molding die 10 for a predetermined time, the foamed metal 20 is produced.

FIG. 4A is a perspective view illustrating a method of manufacturing a condenser for cooling and heating through a method of manufacturing a foamed metal product according to the present invention, and FIG. 4B is a perspective view illustrating a condenser for cooling and heating manufactured by the method of FIG.

4A and 4B, the pipe 50 is embedded inside the forming die 10. When the raw material, the thickener, the foaming agent and the coloring paint are fired and fired and melted in the mold 10 for a predetermined time, a foamed metal ingot 20 wrapping the pipe 50 is generated to generate a cooling / heating capacitor . Although only the condenser for cooling and heating is shown in the drawings, the condenser is applicable to various products such as a heat exchanger and a heat sink by machining to suit the application.

FIG. 5A is a view showing a state where a nut is included in a structure through a method of manufacturing a foamed metal product according to the present invention, FIG. 5B is a view showing a state where a nut is integrally fastened to a structure by the manufacturing method of FIG. to be.

5A and 5B show a state in which the nut 30 is fixed to the inside of the forming die 10 through the fixing jig 32 and then the raw material, the thickener, the foaming agent and the coloring paint are put into the forming die 10 ), It is swollen in the space of the forming mold to produce the structure S including the nut 30. [0044] At this time, the fixing bolt 33 is coupled to the nut 30 to protrude out of the mold frame 10 and then fixed to the fixing jig 32 to prevent the nut 30 from moving during the foaming . Although only the nuts are shown in the drawings, a variety of products such as fixing pins, fixing plates, pipes, pipes, rods, and JiG are inserted into the molding molds, fixed with fixing jigs, and then raw materials, thickeners, foaming agents and coloring materials A structure in which a fixing pin, a fixing plate, a pipe, a pipe, a rod, JiG, etc. are integrally formed can be manufactured.

FIG. 6A is a view illustrating a process of manufacturing an inner wall of a building using the foamed metal product according to the present invention, and FIG. 6B is a view illustrating an inner wall manufactured by the manufacturing method of FIG. 6A fastened to a wall of a building .

6, the inner side of the forming die 10 is formed into a plate shape and the bolt 60 is projected to the outside of the forming die 10 as shown in FIG. 6A. The bolts 60 The thickening agent, the foaming agent, and the coloring paint are put into the inner side after the fixing jig 32 is fixed and the plastic body 10 is fired and melted for a predetermined time, the bolts 60 and the foamed metal 60 are bonded And become one.

6B, the bolts 60 and the nuts 61 can be coupled to the wall W of the building.

6B shows a case of being used for the outer wall surface. However, when the inner wall is used as an inner wall material, only the foamed metal 20 is left when the predetermined volume including the plate 40 is cut on the outer surface. Although the case of FIG. 6 is shown as being used only as inner and outer materials of a building, it can be applied to various types of various products in accordance with other purposes and functions.

FIG. 7A is a perspective view showing a state where a door is manufactured using the foamed metal product according to the present invention, and FIG. 7B is a perspective view showing a door manufactured by the manufacturing method of FIG. 7A.

7, the inner side of the forming die 10 is formed into a plate shape as shown in FIG. 7A, and a cylindrical forming die 71 is formed on one side of the forming die 10, And the shaping bundle 71 is fixed to the fixing jig 32 and the shaping bundle 72 is formed on the upper and lower portions at positions where the hinge is to be coupled to the other side. Then, the raw material, the thickener, the foaming agent, and the coloring paint are put into the inside of the forming mold 10, and the molding and firing are performed in the molding mold 10 for a predetermined time. A forming bolt 75 for a latch bolt is protrudingly formed on one side of the forming bundle 71 so that the latch bolt can be engaged.

When the molding die 10 and the molding rolls 71 and 72 are removed after the firing and melting, the door 70 as shown in FIG. 7B is formed. At this time, since the through hole 73 is formed at the portion where the shaping bundle 71 is removed, the handle can be coupled to the through hole 73. A latch bolt hole 76 communicating with the through hole 73 is formed so that the latch bolt, which is a component of the handle, is coupled to the latch bolt hole 76.

On the other hand, the concave portion 74 is formed on the other side of the through hole 73 where the molding bundle 72 is removed, so that a hinge (not shown) is coupled to the concave portion 74.

Although the case of FIG. 7 is shown only as a door used for a building or the like, the present invention can be applied to various types of products in accordance with other purposes and functions.

Hereinafter, examples of the raw material, the thickener, the foaming agent, and the coloring paint through the above-described method of manufacturing a foamed metal product will be described.

≪ Example 1 >

900 g of aluminum as a raw material, 30 g of sodium as a thickening agent, 40 g of ZrH2 as a foaming agent and 30 g of cobalt as a coloring paint were pulverized, and the powder or the pressed mass was stirred and put into a mold. Thereafter, the aluminum foil was fired and melted for a predetermined time at 700 ° C., followed by foaming and cooling.

The porosity of the foamed aluminum metal fabric produced by the above method was 90% or more, and the production and production efficiency of the homogeneous product were improved by 30% or more as compared with the conventional foamed aluminum metal ingot.

≪ Example 2 >

900 g of aluminum waste material as raw materials, 35 g of Ca as a thickener, 55 g of ZrH2 as a foaming agent and 10 g of cobalt as a coloring paint were pulverized and then stirred powder or pressed lumps were put into a mold. After that, it was fired and melted by 750 degrees for a predetermined time, cooled, and then the mold was removed to produce a foamed metal ingot.

The porosity of the foamed metal fabric prepared by the above method was more than 95%, and the production of the homogeneous product and the production efficiency were improved by 35% or more as compared with the conventional foamed metal fabric.

The reason why the coloring paint is less than the above-mentioned example 1 is that it is contained in a small amount because a coloring paint is already contained in the aluminum scrap material.

The embodiments of the method of manufacturing a foamed metal product of the present invention described above are merely illustrative and those skilled in the art will appreciate that various modifications and equivalent embodiments are possible without departing from the scope of the present invention. You will know very well. Therefore, it is to be understood that the present invention is not limited to the above-described embodiments. Accordingly, the true scope of the present invention should be determined by the technical idea of the appended claims. It is also to be understood that the invention includes all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.

10: forming mold 11: upper housing
12: lower housing 13: bolt
14: Nut 20: foamed metal
30: Nut 32: Fixing jig
33: fixing bolt 40: plate
50: pipe 60: bolt
61: Nut 70: Door
71, 72: forming block 73: through hole
74: recess 75: forming die for latch bolt
76: Latch bolt hole

Claims (7)

(S10) of grinding a raw material composed of aluminum, aluminum scrap, or alloy to form powder;
Stirring the raw material, the thickener, the foaming agent, and the coloring paint of the powder (S20);
Pressing the powder into a lump (S30);
A constituent fixing step S40 inside the forming die 10;
Injecting powder or lumps into the mold 10 (S50);
A step S60 of firing and melting the powder or lump and molding the powder or lump according to the shape of the forming die 10;
(S70) cooling the mold (10) by air cooling or water cooling; and
And removing the forming die (10) (S80). The method according to claim 1,
The raw materials, the thickener, the foaming agent,
Wherein the foaming agent comprises 86 to 96% by weight of raw materials, 1 to 6% by weight of a thickener, 1 to 10% by weight of a foaming agent, and 1 to 8% by weight of a colored paint. 3. The method according to claim 1 or 2,
The raw material,
≪ / RTI > further comprising a ceramic. 3. The method according to claim 1 or 2,
Preferably,
Wherein calcium or sodium is used or calcium is mixed with one or more of nitrogen, oxygen, carbon dioxide, water and argon.
3. The method according to claim 1 or 2,
The blowing agent may contain,
Characterized in that one or both of TiH2, ZrH2, polyvinyl alcohol, polyurethane, polyvinyl acetate, phenol resin, cellulose, sodium phosphate, sodium chloride, calcium chloride, sodium acetate and ferric chloride is mixed Gt; 3. The method according to claim 1 or 2,
The coloring paint may contain,
Wherein at least one of calcium hydroxide, zinc oxide, silicon, Na2, Co3, iron, cobalt, manganese, nickel and copper is mixed.
The foamed metal article produced by the method of claim 1 or 2
Made of foam metal ingots or doors,
Wherein at least one of a bolt, a nut, a JIG, a rod, a plate, a pipe, a pipe, and a fixing pin is inserted into the construct.

Images