WO2009049427A1 - Cellule ouverte, matériau poreux, et procédé pour, et mélange pour, fabriquer ceux-ci - Google Patents

Cellule ouverte, matériau poreux, et procédé pour, et mélange pour, fabriquer ceux-ci Download PDF

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Publication number
WO2009049427A1
WO2009049427A1 PCT/CA2008/001863 CA2008001863W WO2009049427A1 WO 2009049427 A1 WO2009049427 A1 WO 2009049427A1 CA 2008001863 W CA2008001863 W CA 2008001863W WO 2009049427 A1 WO2009049427 A1 WO 2009049427A1
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WO
WIPO (PCT)
Prior art keywords
mixture
open cell
porous structure
cell porous
making
Prior art date
Application number
PCT/CA2008/001863
Other languages
English (en)
Inventor
Dominic Pilon
Alain Harvey
Mario Patry
Original Assignee
Metafoam Technologies Inc.
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Metafoam Technologies Inc. filed Critical Metafoam Technologies Inc.
Priority to CN2008801214744A priority Critical patent/CN101903125A/zh
Priority to EP08839074A priority patent/EP2214851A1/fr
Priority to CA2703020A priority patent/CA2703020A1/fr
Publication of WO2009049427A1 publication Critical patent/WO2009049427A1/fr

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D15/00—Heat-exchange apparatus with the intermediate heat-transfer medium in closed tubes passing into or through the conduit walls ; Heat-exchange apparatus employing intermediate heat-transfer medium or bodies
    • F28D15/02—Heat-exchange apparatus with the intermediate heat-transfer medium in closed tubes passing into or through the conduit walls ; Heat-exchange apparatus employing intermediate heat-transfer medium or bodies in which the medium condenses and evaporates, e.g. heat pipes
    • F28D15/04—Heat-exchange apparatus with the intermediate heat-transfer medium in closed tubes passing into or through the conduit walls ; Heat-exchange apparatus employing intermediate heat-transfer medium or bodies in which the medium condenses and evaporates, e.g. heat pipes with tubes having a capillary structure
    • F28D15/046—Heat-exchange apparatus with the intermediate heat-transfer medium in closed tubes passing into or through the conduit walls ; Heat-exchange apparatus employing intermediate heat-transfer medium or bodies in which the medium condenses and evaporates, e.g. heat pipes with tubes having a capillary structure characterised by the material or the construction of the capillary structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
    • B21C37/06—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes
    • B21C37/08—Making tubes with welded or soldered seams
    • B21C37/09—Making tubes with welded or soldered seams of coated strip material ; Making multi-wall tubes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/11—Making porous workpieces or articles
    • B22F3/1121—Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/10—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
    • B22F5/106—Tube or ring forms
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/002—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature
    • B22F7/004—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature comprising at least one non-porous part
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F2005/005—Article surface comprising protrusions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy

Definitions

  • the present invention relates to porous materials, methods of making porous materials, ami mixtures for making porous materials.
  • Porous metal or ceramic materials are currently used for the fabrication of devices such as filters, heat exchangers, sound absorbent, electrochemical cathodes, fuel cells, catary.it supports, fluid treatment units, lightweight structures and bi ⁇ materials.
  • the invention described in Ae '224 patent is a porous material thai is produced by heating a dry powder mixture containing mainly an organic solid binder and inorganic particles. The mixture is foamed while the organic' binder is melted. Foaming comes from a foaming agent in the powder mixture. The resulting solid foamed structure that comprises the inorganic particles embedded in the organic binder is next heated to cure and then eliminate Uic organic binder and final Iy io sinter the remaining inorganic three-dimensional network into a rigid structure having interconnected porosity.
  • porous material described in the '224 patent arc particularly well suited for use in working-liqiiid-phasc- change heat transfer devices, such as heat pipes and vapor chambers.
  • working-liqiiid-phasc- change heat transfer devices such as heat pipes and vapor chambers.
  • working-liquid-phase-ehange heat transfer devices that lequiie a porous material with an even greater wicking capacity and smaller pore size than is possible to obtain hy lollnwi ⁇ g the methods described in the '224 patent. No other suitable method exists for producing such materials.
  • Tt is also an object of the present invention to provide an open cell porous material, and a method of, and mixture for, making same, where the material is suitable for use in certain worki ⁇ g-liquid-phase-chauge heal transfer devices.
  • the invention provides a method for making an open cell porous structure, comprising: (a) Providing a dry flowablc powder mixture including (i) a first predetermined amount of inorganic particles having a firsi melting temperature, (ii) a second predetermined amount of a binding agent having a decomposition temperature, the decomposition temperature being lower than the first melting temperature, and (iii) an absence of foaming agent (in.
  • the metal is oxidized and it is the oxygen atoms that are interconnecting the metal atoms and bonding the structure together.
  • the binder be cleanly decomposed, i.e. that it leaves no residue behind after its decomposition, (d) healing the uo ⁇ -ineiallurgically-bonded open cell porous structure to a temperature lower than the first melting temperature Io mclalluryieally bond the inorganic particles and obtain a solid metallurgically bonded open cell porous structure.
  • healing the non- metallurgically-bondcd open cell porous slruekire Io a temperature lower than the first melting temperature l ⁇ meiallurgieally bond the inorganic particles and obtain a solid metallurgically bonded open cell porous structure comprises heating the ⁇ e- ⁇ -metallurgically-bonded open cell porous structure to a temperature lower than the first melting temperature tu sinter the inorganic particles and obtain a solid sintered open cell porous structure.
  • Sintering is usually accomplished by healing the structure to a temperature between 70% and 90% of the melting temperature of the metal to be sintered- Sintering in most esses will not eliminate the oxygen atoms bul will create direct metal atom to metal atom bonds.
  • the present inventors have observed than in some situations, particularly where the material to be made is of reduced thickness (e.g. less than 2 mm), damage or destruction of material does not occur notwithstanding the fact that there is no foaming agent present in lhc mixtuie from which die material is being produced.
  • the absolute Iimil for any particular material before damage or destruction occurs will vary depending on the shape of the material, tins composition of the inorganic particles from which the material is being produced, and the nature and type of binding agent being used. Simple visual inspection of the material will allow one to determine whether the limit has been passed. Owing to the absence of foaming agent, the voids present in materials of the '224 patent that are created by the foaming agent are not present in materials of the present invention.
  • the capillary radius of capillaries of materials of the present invention is smaller (i.e. in the order of between 50 100 microns) versus those in the materials of (he '224 patent (i.e. greater than 100 microns); the permeability of materials of the present invention is lower (i.e. in the order of between 9.4xlO "12 m 2 to 1.3x10 " " m 2 than that of the materials of the '224 patent (Le, higher than 1.3x 10 " " " m 2 ).
  • Materials of the present invention thus have a significantly greater wicking strength and an equivalent or inferior pumping speed than materials of the '224 patent. Materials of the present invention can thus he used in applications ( «. ' .#. certain executions of wnrking-liquid-phase-cha ⁇ ge heat transfer devices) for which materials of lhe : 224 patent are not appropriate.
  • materials of the present invention are dillerent lhan eonventional sintered powder materials.
  • the capillary radius of capillaries of materials of the present invention is higher (i.e. in the order of between SO 100 microns) versus those in conventional sintered powder materials (i.e. lower than 50 microns); the permeability of materials of the present invention is higher (i.e. in the order of between 9.'4 ⁇ .lQ *12 m 2 to J .3x10 " ttt 2 l.l ⁇ a ⁇ that of
  • Cu ⁇ vc ⁇ lioiiat sintered powder materials i.e. lower lhan 9.4x.lO' 12 m J .
  • Materials of the present invention thus have a tower wicking strength and significantly higher pumping speed than conventional sintered powder materials. Materials of the present invention can thus be used in applications (e g. certain executions of working-liquid-phase-change heat transfer devices) for which conventional sintered powder materials are not appropriate.
  • the first predetermined amount of inorganic particles is between about U) wt % to about 90 wt % inclusive of a total weight of the mixture. More preferably, the first predetermined ainouni is between about 40 wi % ID about 90 wt % inclusive of the total weight of the mixture. Still more preferably, the first predetermined amount is between about 55 wt % to about 80 wt % inclusive. Most preferably it is between 60 wt % to about 75 wl % inclusive. The first predetermined amount is selectable by persons skilled in the art according to the final use of the material to be made.
  • thai lirst predetermined amount will be at the relatively high end of the ranges disclosed (e.g. about 75 wl % or highet).
  • first predetermined amount will be at the relatively low end of ll ⁇ ranges disclosed (e.g. about 60 wt % or lower).
  • the second predetermined amount of binder agent be between ⁇ bout 10 wl % to about 90 wt % inclusive of the total wciAbl of the mixture. More preferably, the second predetermined amount is between about 20 wl % to about 35 wl % inclusive.
  • the inorganic particles and the binding agent arc present (e.g. metallic particles and a thermoset binding agent)
  • the wt % of the binding agent will he directly related to the wt % of the inorganic particles.
  • the binding agent will likely be the vast majority of the wt % of the mixture that is nut inorganic particles.
  • the inorganic particles consist essentially of iioii-rnelallic particles (preferably ceramic particles), metallic particles, or combinations thereof.
  • the selection will depend on the final use to which the material being made is put, and lhus lhe required characteristics thereof (e.g. thermal conductivity, electrical conductivity, wicking capacity, absorptive capacity, etc.).
  • metallic particle it is preferred (hat the particles be at least one of metal particles and metal alloy particles.
  • the metallic particles be metallic particles of at least one transition metal, and preferably at least one transition metal selected from the group consisting of scandium, titanium, vanadium, chromium, manganese, iron, coball, nickel, copper, ytlrium, zirconium, niobium, molybdenum, ruthenium, rhodium, palladium, silver, hafnium, tantalum, tungsten, rhenium, osmium, indium, platinum, and gold. More preferably, the metallic particles arc ai least one selected from the group consisting of copper, nickel, iron, titanium, copper-based alloy particles, nickel-based alloy particles, iron-based alloy particles, and titanium-based alloy particles. Most preferably the metallic particles are ai least one. uf copper and copper-based alloy particles. These materials are preferred given their ability to be (relatively) easily sintered.
  • the inorganic- particles consist essentially of coated particles.
  • the particles may be coated hy chemical reaction ⁇ e.g. an aluminum particle will generally oxidize in an oxidizing environment to produce an aluminum particle with an aluminum oxide coating ⁇ i.e. outer layer)) or by mechanical deposition ( «.#. a copper particle mechanic-ally coated with a silver-based brazing agent)
  • the binding agent be a thc ⁇ noscl resin or a thermoplastic polymer. Suitable resins and polymers are well known in the art. La such cases, it is preferred that the binding agent be blended with fhe other components) of the mixture by dry mixing or milling. Where the binding agent is a thermoplastic polymer, it is preferred that the binding agent be cured with the aid of a curing agent, or alternatively by an irradiation cross-linking treatment, or a. li ⁇ hl-exp ⁇ sure cross-linking treatment
  • the mixture farther include at least one additional agent adapted to minimise segregation and dusting and to improve the flownbility of the mixture.
  • additional agent adapted to minimise segregation and dusting and to improve the flownbility of the mixture.
  • Such agents are well known in the art. ⁇ n example would be a fine silica power that is added to the mixture in a very small amount ⁇ e.g. less than 0.01 wt %) where the mixture is to be injection molded or extrusion molded.
  • Tl is picferrcd lhat the mixture be subject to successive increases of temperature during execution of (b), (c), and (d) set forth above.
  • the temperature be increased in a stepwise manner.
  • pressure be applied t ⁇ the mixture at least one of k-lbre and during the heating thereof in (b), (c) or (d) as set ibrth above.
  • Pressure can be used for various purposes depending on at which point in the process the pre ⁇ sure is being applied. Kor example, pressure in the order of 206 kPa to 278 kPa (30 to 40 psi), applied via an hydraulic press exerting force on the mold containing the mixture, can be used before (b) in order to ensure a smooth finish to the final materia!
  • the method further comprise shaping the mixture, preferably before it is heated. Tn such cases it is preferred that the shaping be carried out via at least one of molding, deposition, lamination, and CXI ⁇ UMUII.
  • the intermediate or final structure can be machined through (he use of a numhci of conventional machining l.cdmk
  • the method further comprise providing a substrate, and that the mixture be disposed on the substrate prior to (d).
  • a substrate may be a cupper plulc where the material will be used in a vapor chamber.
  • the copper plate provides good thermal conductive properties as well as mechanical support for the material, enabling it Io helter serve its intended function irt lhe vapor chamber.
  • the mixtures further comprise at least one spacing ayent.
  • a spacing agent is added to mixtures to occupy Space during lhe formation of the materials, which will create a void in the material when the spacing agent is removed.
  • An example is a salt, that is not affected by the application of heat during the manufacturing process, but that can be removed Horn die final material by being dissolved in u ⁇ appropriate liquid (i.e. by leaching), usually water.
  • the at least one spacing agent be a scaffold. It is also preferred thai ihc ai leasl one spacing agent be removed by at least one of thermal decomposition and leaching.
  • the mixture further comprise at least one brazing agent to metallurgical ⁇ bond the inorganic particles, as is described in international patent application I 1 CT/CA2OO7/OOO679 filed April 23, 2007 entitled "Open Cell Porous Material and Method for Producing Same” published as WO 2007/121575 Al on November 1, 2007 (which is incorporated herein by reference).
  • Brazing is usually used in place of sintering (as opposed to in addition U>).
  • a bra/ing agent creates a solid solder-like bond hetween adjacent particles which results in n material having generally improved mechanical properties.
  • brazing is achieved at a tower temperature and in a shorter time than a conventional sintering step, and can thus lead to reduced manufacturing time and reduced energy costs.
  • Many conventional brazing agents exist are silver, copper or eadmium-based powders.
  • the invention provides an open cell porous structure made according to the methods described hereinabove, as well as to a mixture as described above used therein.
  • Embodiments of the present invention each have at least one of the above-mentioned objects and/or aspects, but do not necessarily have all of them. It should he understood that some aspects oi "the present invention that have resulted from attempting to attain the above- mentioned objects may not satisfy these objects and/or may satisfy other objects not specifically recited herein.
  • the porous material according to (he present invention is produced from a dry flownble powder mixture comprising a base material and a binding agent, eaeh provided in predetermined amounts, and having an absence ftf tf.e. no) foaming agent.
  • the base material includes inorganic particles having a first melting temperature
  • the binding agent is preferably, b ⁇ ( not exclusively, an organic binder having a decomposition temperature lower than the first melting temperature and having clean bum out characteristics. All of these materials arc readily available from appropriate commercial suppliers.
  • the exact amount of each constituent of the mixture is determined, prior to the execution of the method of the present invention, based on the physical and chemical properties of the inorganic particles and of the binding agent, and based on the desired properties of the finished open cell porous structure. Consequently, the exact composition of the mixture will vary according to the nature of the base material and of the binding agent.
  • Tlie inorganic particles comprise metallic particles, metallic alloy particles, ceramic particles, coated particles and/or a combination thereof.
  • the metal or metals are preferably transition metals (e.g. copper, nickel, iron) as defined by the periodic table of elements.
  • the inorganic particles will have a first melting temperature.
  • the inorganic particle content may be between about 10 to about 90 wt % inclusive of the total weight of the mixture (preferably between about 40 Io about 90 wt % inclusive, more preferably between about 55 wt % to 80 wt % inclusive, still more preferably between about 60 wt % to 75 wt % inclusive).
  • the exact amount of the Inorganic particles and the choice thereof will be determined by the skilled addressee depending on the requirements of the application for which the open cell porous material is being manufactured.
  • the hinder used in the mixture is preferably an organic binder provided in a dry llowable powdered form and with clean bum out characteristics.
  • the binder can be a thermoplastic polymer, a the ⁇ noset resin and/or a combination thereof.
  • the binder can also he an inorgnnic binder, a synthetic binder or a mixture of, organic and/or inorganic and/or synthetic binders.
  • the binder may be provided in solid form (preferably powder particles), in semi-solid funn, HI liquid form, in gel form or in semi-liquid form.
  • the binder has a decomposition temperature lower than the first melting temperature of the inorganic particles in order to prevent premature melting of the inorganic panicles during the decomposition step.
  • the binder content in the mixture may vary from about 10 to about 90 wt % of (he (olal weight of the mixture, the exact amount thereof will be determined by the skilled addressee depending on the nature of the inorganic memelielvs and on the requirements of the npplication for which the open cell porous material is being manufactured. Most preferably, the binder should no decomposition products in the porous structure. However, some residues can be accepted if they do not negatively affect the final properties of the final product or if they improve some of Hs properties.
  • the mixture may comprise a curing agent ⁇ e.g. a cross-linking) agent to induce faster Curing of the hinder during or after the curing step and improve lhc mechanical strength of the cured structure before the decomposition of the binder.
  • a curing agent e.g. a cross-linking
  • the mixture may also comprise other additives such as a lubricant to ease shaping, molding or demolding, or flowing agents to improve the flowability of the powder when all the constituents arc in powdered form.
  • the organic binder can be blended with the other constituent using various techniques such as, but not limited to, mixing, milling, mixing the binder in suspension or in solution in a liquid, blending the binder in molten, liquid, gel or semi-liquid form with the inorganic particles and the other additives. Whichever mixing technique is used, the resulting product should be a curable mixture.
  • a spacing agent may be added to the mixture to provide additional porosity and to improve pore connect ivjiy.
  • a spacing agent is removed after curing to leave voids in the structure after decomposition of the binder or after sintering.
  • the spacing agent can be removed by thermal decomposition after curing or by leaching after curing, decomposition of lhc binder Or sintering.
  • the spacing agcvil can be parlidcs or a scaffold. When particles are used, they arc admixed with the rest of the mixture.
  • the spacing agent can be polymeric particles admixed with the mixture.
  • the spacing agent concentration can vary from about 5 to 50 wt % inclusively, but preferably between 10 and 30 wt % inclusively.
  • the scaffold is, tor example, a polymeric foam, that can be filled with the mixture and removed by the ⁇ al decomposition or by leaching, It is also contemplated to add additional binder in amount varying between 0.05 wt % to
  • This adUniunal binder may be generally used to bind different constituents of the mixture together in such n. wny thnt the final product is less prone to segregation and/or dusting.
  • the additional binder may be added at different steps of the mixing procedure, cither before mixing the inorganic particles with the binder, after the binder addition, after the lubricant addition, after the flowing agent addition or after the addition of any combination ⁇ flhosc constituents. Whichever mixing technique is used, the resulting product should be a curable mixture.
  • Tlic resulting mixture may be shaped using methods such as molding, deposition, lamination or extrusion.
  • the product is then heated at a moderate temperature to melt the binder, if the latter is not already in liquid, gel or ic ⁇ ii-ljquid form, and to initiate the curing of the mixture,
  • pressure may be applied Io the mixture before or during heating the mix lure.
  • the porosity and structure of the resulting open cell porous material will depend on the particle size, shape, density and content of the inorganic particles; the content and viscosity of the hinder, as well as the processing conditions. However, in most cases the material will haw two pore groups, namely a first pore group and a second pore group.
  • the first pore group has an average pore UM in the range from about 20 ⁇ m to about 200 ⁇ r ⁇ , preferably in the range from about 40 ⁇ m to aboul ISO ⁇ i ⁇ and most prvfciahly from about 60 ⁇ m to about lOO ⁇ m. In each case the standard deviation is in the range from about lO ⁇ m to about IGO ⁇ m.
  • the first pore size group constitutes from about 50% to about 80% of the void volume of the metallic porous structure.
  • the second pore group has an average pore size in the range from about 25Unni to about 15 ⁇ m, preferably in the range from about SQOiim to about 15 ⁇ m and most preferably from about 500 ⁇ i ⁇ to about lOum. Iu each case the standard deviation is in the range from aboul 200nm to about l ⁇ m.
  • the second pore size group constitutes from about 20% to about 50% of the void volume of the metallic porous structure.
  • the capillary radius will be an average of the two p ⁇ re groups, thus on average, relatively low because of the second pore group.
  • the first pore group will lead to a high permeability. Hence the structure provides a high permeability and low capillary radius leading to a high pumping speed.
  • K) Materials can be cured in a mold Io provide three-dimensional porous stiiictuies
  • the mixture can be cured on or in a substrate to ptoducc a coating or to produce composiU; structures. Curing can be done ll>r example on a plate, on a rod, in or outside a tube or cylinder, in or on other porous structure (mcsli, beads, (bam for example) or any other substrate,
  • the material can be machined after curing, decomposition oi ' lhc binder or sintering.
  • h ⁇ nctionally grnded materials can be produced using mixtures with variable composition.
  • Graded layered structures can be produced for example by deposing layers of mixtures with different composition.
  • Functionally j ⁇ radetl materials can also be produced by controlling the thermal gradient during curing in order to control material curing and pore t>uc distribution.
  • the mechanical strength of the cured structure may be further increased, before decomposition of the binder and Sintering, by using externally assisted eruss-linking techniques such as irradiation or light exposure.
  • the cured mixture is treated at a sutt ⁇ eiently high temperature to decompose the binder.
  • the atmosphere (with or without the presence of oxygen), duration and leinperauue of the thetmal treatment should preferably allow a clean decomposition of the binder.
  • Hinder decomposition should preferably not deteriorate the three- dimensional structure of the Cured mixture. If gas pressure generated during binder decomposition is too great, cracking in or destruction of the still unmetallurgically-bo ⁇ dcd structure may occur. Oxidizing or reducing conditions during the thermal treatments may be chosen to optimize binder decomposition.
  • the cured structure is composed of open cell metal (usually oxidized metal), and/or metal alloy (usually oxidized metal alloy), and/or ceramic material particles.
  • Sintering is done after the decomposition of (he binder to create bonds between the inorganic particles of the cured mixture.
  • Sintering conditions temperature, time and atmosphere
  • Sintering conditions should be such that the inorganic particles do not melt to create the bond between them; conditions should be such that the material particles adhere to each other through a bond mainly created by solid-state diffusion to form a strong metallurgical joint between them.
  • Effective solid-state diffusion occurs between material panicles when they are heated, for a certain lime, at temperatures slightly under the inching temperature of the material particles.
  • Sintering is generally done in reducing atmosphere for metal particles to avoid the formation of surface oxides on the structure and to reduce lhe oxides that were present prior to sinteruig.
  • Mechanical strength may be adjusted for the application.
  • the choice, size, nature and/o ⁇ physical state of the inorganic particles and of the binder content will have a .substantial U influence of the physical properties (e.g. mechanical strength) of the produced open cell porous material.
  • the internal surface of the structure can be modified for example by heat treatment, chemical treatment or deposition of coatings using various state of the art deposition techniques.
  • the external surfaces of the structure can be modified for example by a stumping, etching, embossing, or grooving leelumjuc and by state of the art surface coating techniques.
  • the structure.- tan be integrated in other products and/or to other structures using different state of the art techniques such as diffusion bonding, press fitting, welding, brazing, sintering or gluing. The invention is not so limited.
  • n metallic open cell porous structure with copper (Cn) as the base material, was produced from a mixture having the formulation presented the table below.
  • the different constituents were dry-mixed together until the mixture became hum ⁇ enwus. After mixing, the mixture was poured into a mould and cured at 110"C in air for 2 hours. After curing, the material was submitted for the decomposition of the binding agent in a furnace at 650 0 C for 4 hours in u dry air stream. Finally, the material was sintered in a
  • a metallic open cell porous structure with nickel (Ni) as 5 the base materia), was produced from a mixture having the formulation presented the table below.
  • u metallic open cell porous structure with iron (Fe) as the base material, was produced from a mixture liaving the formulation presented the table below.
  • the different constituents were dry-mixed together until the mixture became homogeneous. After mixing, the mixture was poured into a mould and cured at 1 H) 0 C in air for 2 hours. Alter curing, the material was submitted for the decomposition of the binding agent in a furnace at 6.1O 0 C 1'or 4 hours in a dry air stream. Finally, thy material was sintered in a 75%Ar/25%TI 2 atmosphere for 2 hours at 1400 0 C.
  • Example 4 lii a fourth specific example, a metallic open cell porous structure, with copper (Cu) as the base material, was produced from a mixture having the formulation presented in the table below.

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  • Physics & Mathematics (AREA)
  • General Engineering & Computer Science (AREA)
  • Composite Materials (AREA)
  • Materials Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Powder Metallurgy (AREA)
  • Cooling Or The Like Of Semiconductors Or Solid State Devices (AREA)

Abstract

Le matériau poreux de la présente invention est produit en chauffant un mélange de poudre sec, contenant principalement un liant solide organique et des particules inorganiques et ne contenant aucun agent moussant. Le mélange est chauffé pour fusionner avec le liant organique. La structure solide résultante comprenant des particules inorganiques intégrées dans un liant organique est ensuite chauffée pour éliminer le liant organique, et pour finir chauffée de nouveau pour lier métallurgiquement le réseau tridimensionnel inorganique restant à l'intérieur d'une structure rigide ayant une porosité interconnectée.
PCT/CA2008/001863 2007-10-19 2008-10-20 Cellule ouverte, matériau poreux, et procédé pour, et mélange pour, fabriquer ceux-ci WO2009049427A1 (fr)

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CN2008801214744A CN101903125A (zh) 2007-10-19 2008-10-20 开孔多孔材料、其制备方法及用于制备其的混合物
EP08839074A EP2214851A1 (fr) 2007-10-19 2008-10-20 Cellule ouverte, matériau poreux, et procédé pour, et mélange pour, fabriquer ceux-ci
CA2703020A CA2703020A1 (fr) 2007-10-19 2008-10-20 Cellule ouverte, materiau poreux, et procede pour, et melange pour, fabriquer ceux-ci

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PCT/CA2007/001874 WO2009049397A1 (fr) 2007-10-19 2007-10-19 Dispositif de gestion thermique utilisant de la mousse inorganique
CAPCT/CA2007/001874 2007-10-19

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CN110756812B (zh) * 2019-10-25 2021-10-26 安徽省新方尊自动化科技有限公司 一种基于钎焊的通孔泡沫铝生产工艺
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CN102234187A (zh) * 2010-04-29 2011-11-09 比亚迪股份有限公司 一种陶瓷复合材料及其制备方法

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CA2702997A1 (fr) 2009-04-23
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CN101903125A (zh) 2010-12-01
WO2009049397A1 (fr) 2009-04-23

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