WO2013176450A1 - Method for preparing metal foam product and metal foam product using same - Google Patents

Abstract

The present invention relates to a method for preparing a metal foam product and a metal foam product using the same, and more specifically, to a method for preparing a metal foam product and a metal foam product using the same, wherein a worker can readily produce an aluminum foam, an alloy foam, a ceramic foam and the like with a desired shape without an additional step of processing a metal form with a desired shape after forming the metal foam, and thus there is no loss of materials and productivity is increased. The present invention comprises the steps of: pulverizing a material comprising any one of aluminum, aluminum waste materials, and alloys to form a powder; stirring the powdered material, a thickener, a foaming agent, and a coloring paint; pressing the powder into lumps of a predetermined size; fixing constituent elements inside a molding frame; injecting the powder or the lumps into the molding frame; firing and melting the powder or the lumps to mold the same according to the shape of the molding frame; cooling the molding frame by air or water; and removing the molding frame.

Description

Foamed metal product manufacturing method and foamed metal product using same

The present invention relates to a method for manufacturing a foamed metal product and a foamed metal product using the same, and more particularly, to easily produce foamed aluminum, foamed alloy, foamed ceramic, etc. in a desired shape without a subsequent process of processing the foamed metal into a desired shape. The present invention relates to a method for manufacturing a foamed metal product and a foamed metal product using the same.

In general, the foamed metal is a porous metal having a large number of bubbles in the material and is largely divided into an open cell type and a closed cell type. In the case of alveolar foam metal, bubbles inside the metal do not connect, but exist independently.In the case of open-cell foam metal, pores in the material are connected to each other, so that gas or fluid can be easily passed in comparison with the alveolar foam metal. Is diverse.

These porous metals are highly efficient, small and lightweight aircraft, automobiles, power plants, heat exchangers of power devices, heat dissipation of semiconductors or various electronic products, silencers for large plants, catalysts in chemical plants, aircrafts requiring high strength and ultra-light weight, It is used in various fields such as structural materials, shock absorbers, fuel cells, filters, shock absorbers, electromagnetic shielding, interior construction, and exterior materials in the aerospace industry.

As the porous metal foamed metal, foamed aluminum is generally used, and the aluminum foamed metal contains a myriad of bubbles therein. Since the foamed aluminum usually has a porosity of 90 -95% or more, the specific gravity is in the range of 0.2 to 1.0, and is extremely light, and the material is excellent in sound absorption, sound insulation, and shock absorption due to the pores. In addition, since the raw material is aluminum, it has excellent fire resistance, rigidity, and excellent workability, and is widely used as a functional material.

In order for the aluminum foam metal to have the characteristics described above, the shape or size of the pores present in the metal must be constant, and the productivity of the aluminum foam metal must be improved.

[Preceding technical literature]

[Patent Documents]

(Patent Document 1) Published Patent 10-1997-21338

The above-mentioned patent document is injecting aluminum ingots into a cylindrical crucible and sequentially adding them while melting and stirring the thickener and blowing agent and stirring them to be uniformly mixed, and maintaining the mixture at a temperature above the melting point while dropping the mixture into the mold. Disclosed is a technique for producing a foamed aluminum metal solid comprising a step of generating and growing bubbles, and cooling and post-processing the foam mold.

As the thickener added during the production of the aluminum foam metal, 1-5% by weight relative to the molten aluminum in the range of 660-750 ° C. is used, and TiH 2 is used as the blowing agent.

However, in the case of the foaming agent, there is a problem that acts as a major factor in increasing the production cost of the product because the decrease in efficiency and loss of raw materials, which are lost about 95% during manufacture.

In addition, after closing the slide valve of the crucible and injecting the molten aluminum metal into the inside of the upper crucible, the thickener is added while operating the stirrer, and when the viscosity of the aluminum molten metal increases over a certain time, the blowing agent is added, the blowing agent diffusion stirring After this, the slide valve is opened and the homogeneously mixed molten metal is dropped on the lower mold heated to an appropriate temperature and cooled to form a desired foamed aluminum metal mass. The foamed aluminum metal mass thus formed is cut to a predetermined size and shipped.

However, when the foamed aluminum metal is manufactured in this way, 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 molten aluminum metal so that it is not easy to mix with the molten aluminum aluminum foam. When the aluminum metal ingot was made, there was a problem that uneven bubbles were generated, such as large bubbles in the upper layer or unfoamed portions in the bottom surface.

In the case of the foamed aluminum metal ingot, only the batch type is formed, so that the foamed aluminum metal ingot is cut again according to the required standard. This cutting operation is extremely difficult, and the powder of the foamed aluminum metal ingot is generated a lot. Raw material loss was a big problem.

The present invention has been invented to solve the above problems, the purpose of which is to utilize the desired shape and function according to the purpose of use, it was conventionally limited to foamed aluminum, various fields such as foamed metal, foamed alloy, foamed ceramic, etc. It is easy to produce foamed products by applying it to, thereby increasing the productivity and function of the product is intended to facilitate its use.

In addition, the present invention is a method of melting the ingots in the existing crucible is made of powder and put into the mold of the product to be produced, and then fired and melted, and used to increase the loss of material and the efficiency of production work have.

The present invention for achieving the above technical problem is a step of pulverizing the raw material consisting of any one of aluminum, aluminum waste material, alloy; Stirring the raw materials, thickener, foaming agent, and coloring paint of the powder; Pressing the powder into a lump of a predetermined size; Fixing a component inside the mold; Injecting powder or agglomerates into the mold; Calcining and melting the powder or agglomerate and forming the powder or agglomerates according to a shape of a mold; Cooling the mold to air or water cooling and removing the mold.

In one embodiment, the raw material, the thickener, the foaming agent and the coloring paint, raw material 86 to 96% by weight, thickener 1 to 6% by weight, foaming agent 1 to 10% by weight, coloring paint 1 to 8% by weight It is done.

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

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

In one embodiment, the blowing agent, any one or more of TiH2, ZrH2, polyvinyl alcohol, polyurethane, polyvinyl acetate, phenol resin, cellulose, sodium phosphate, sodium chloride, calcium chloride, sodium acetate, ferric chloride It is characterized by being mixed.

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

Another aspect of the invention is characterized by consisting of any one of the foamed metal ingot, bolt, nut, JIG, rod, plate, pipe, tube, fixing pin by the above method.

According to the method of manufacturing the foamed metal product of the present invention, first, raw materials, thickeners, foaming agents, and coloring paints are simultaneously added to the inside of the mold to shape and melted to form a foamed metal product. There are no missing parts, so it is possible to obtain high quality foamed metal products and to prevent material loss.

Second, since the user forms a mold of the desired shape, there is no separate cutting and pressing after forming the foamed metal, and thus the workability is increased, and the mold formed once can be used continuously, thereby increasing the efficiency and economic efficiency of the work. .

Third, raw materials, thickeners, foaming agents, and coloring paints can be selectively used depending on the purpose of use, thereby increasing the applicability and functionality of the product.

Fourth, since the coloring is added to the foam when foaming together, it does not need to be applied to the surface of the foamed metal separately, there is an effect of simplifying the work.

1 is a process chart showing the process sequence of the method for producing a foamed metal product of the present invention.

Figure 2a is a view showing a state of producing a foamed metal mass through the foamed metal product manufacturing method according to the present invention.

FIG. 2B is a perspective view illustrating a foamed metal mass formed by the method of FIG. 2A. FIG.

Figure 2c is a view showing a state in which the expanded metal mass of Figure 2b utilized in many ways.

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

Figure 4a is a perspective view showing a state of manufacturing a cooling and heating capacitor through a method of manufacturing a foamed metal product according to the present invention.

Figure 4b is a perspective view showing the appearance of a cooling and heating capacitor manufactured by the manufacturing method of Figure 4a.

Figure 5a is a view showing a state including a nut in a structure through a method for producing a foamed metal product according to the present invention.

Figure 5b is a view showing a state in which the nut is integrally fastened to the structure by the manufacturing method of Figure 5a.

Figure 6a is a view showing a state of manufacturing the inner wall of the building using a foamed metal product according to the present invention.

6B is a view showing a state in which an inner wall manufactured by the manufacturing method of FIG. 6A is fastened to a wall surface of a building.

Figure 7a is a perspective view showing a state of manufacturing a door using a foamed metal product according to the present invention.

FIG. 7B is a perspective view illustrating a door manufactured by the manufacturing method of FIG. 7A. FIG.

In order to fully understand the present invention, preferred embodiments of the present invention will be described with reference to the accompanying drawings. Embodiment of the present invention may be modified in various forms, the scope of the invention should not be construed as limited to the embodiments described in detail below. This embodiment is provided to more completely explain the present invention to those skilled in the art. Therefore, the shape of the elements in the drawings and the like may be exaggerated to emphasize a more clear description. It should be noted that the same members in each drawing are sometimes shown with the same reference numerals. In addition, detailed descriptions of well-known functions and configurations that are determined to unnecessarily obscure the subject matter of the present invention are omitted.

Hereinafter, with reference to the accompanying drawings illustrating a preferred embodiment of the present invention, a method for producing a foamed metal product of the present invention will be described in detail.

1 is a process chart showing the process sequence of the method for producing a foamed metal product of the present invention.

Referring to FIG. 1, in the method for manufacturing a foamed metal product of the present invention, first, an raw material made of any one of aluminum, aluminum waste material, and alloy is pulverized to form a powder (S10). In this case, the raw material may further include ceramics, and thus, foam products may be manufactured through various materials. The above-mentioned foam ceramic is used for interior and exterior materials and wood replacement of buildings, and in addition, there is no environmental pollution as a non-toxic eco-friendly ceramic such as a catalyst and a filter.

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

On the other hand, it is preferable that the above-mentioned raw materials, thickener, foaming agent, and coloring paint are stirred at 86-96% by weight of raw materials, 1-6% by weight of thickener powder, 1-10% by weight of blowing agent, and 1-8% by weight of coloring paint. . Depending on the type of raw material, the above-described thickener, foaming agent, colored paint may be changed in content.

In addition, the thickener may be composed of any one of calcium, sodium, nitrogen, oxygen, carbon dioxide, water, argon. In the above-described composition, two or more compositions may be contained depending on the kind and use of the raw materials.

In addition, 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, ferric chloride. In the above-described composition, two or more compositions may be contained depending on the kind and use of the raw materials.

In addition, the coloring paint, calcium hydroxide, zinc, silicon, carbon dioxide, ArH2, Na2, Co3, iron, cobalt, manganese, nickel, copper may be composed of any one. In the above-described composition, two or more compositions may be contained depending on the type of raw materials and the intended use.

Thereafter, the respective compositions stirred as described above are inserted into the mold 10 (S30). The mold 10 is composed of an upper housing 11 and a lower housing 12, the rib is formed at the edge is fastened by the bolt 13 and the nut 14 to be sealed. Although separated into upper and lower housings in the drawing, it is possible to manufacture and use a single mold according to the manufactured product. In addition, by attaching a plate-shaped plate 40 to the inner wall surface of the mold 10, the foam metal 20 and the plate 40 can be integrally formed when the raw material, thickener, foaming agent, coloring paint is foamed Can be configured to

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

Then, to fix the configuration inside the mold 10 (S40). Here, the configuration may be directly formed in an intaglio or embossed on the inner surface of the mold 10, it is to fix the bolt 60 or the nut 30 itself in the mold 10. In addition to the bolt or nut, IG, rods, plates, pipes, pipes, fixing pins, etc. may be fixed.

Subsequently, the mixed powder or agglomerate is introduced into the mold 10 (S50).

Thereafter, the powder or agglomerates is melted and molded according to the shape of the mold 10 (S60). In this case, the melting temperature is preferably 600 to 800 degrees in the case of aluminum or alloy, and preferably 1000 to 1200 degrees in the case of metal or ceramic. Therefore, the powder or lump is swelled while melting to fill the mold 10 tightly. At this time, the bolt 60 or the nut 30 is fixed to the inside of the foamed metal 20 to be integrally formed with the foamed metal 20.

After that, when the foaming is completed, the mold 10 is cooled by air or water (S70).

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

Since each product such as a metal ingot, a bolt, and a nut inserted therein can be shipped through only a slight trimming process after removing the mold 10 and cooling by air or water, waste of raw materials. Can increase the economic efficiency, thereby increasing the convenience and efficiency of the work. In addition, the safety of the worker is secured because it is manufactured through the molding die.

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

Figure 2a is a view showing a state of manufacturing a foamed metal mass through the foamed metal product manufacturing method according to the present invention, Figure 2b is a perspective view showing a foamed metal mass formed by the method of Figure 2a, Figure 2c is a It is a figure showing the use of expanded metal in various ways.

The embodiment of FIG. 2 illustrates the manufacture of a metal mass and shows a raw material, a thickener, a foaming agent and a coloring paint in a forming mold 10 composed of an upper housing 11 and a lower housing 12 as shown in FIG. 2A. After stirring and injecting, after baking or melting for a predetermined time in the mold 10, the respective compositions are inflated by a blowing agent to produce a foamed metal mass 20 as shown in Figure 2b.

The foamed metal mass produced as described above can be used as the metal mass itself. As shown in Figure 2c it is possible to use by cutting for each part. For example, when the area is relatively large, such as the flat portion and the bottom portion, it can be used for the wall surface of the building, etc., the foamed metal 20 formed on the inside can be used for the protective wall which is one of the building material, sound absorbing material or military facilities of the building. For example, when a shell explodes in a firewall, the general steel plate is torn, but in the case of the foamed metal 20, since the pores are formed on the surface, the shell is bent or folded when the shell falls, so that the inside of the firewall is safely protected. will be.

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

3, the embodiment of FIG. 2 is the same as the foamed metal product manufacturing method. However, the shapes of the upper and lower housings 11 and 12 are different, and the inner surface of the upper and lower housings 11 and 12 is embossed or engraved to form a shape according to the user's intention. After the powder or agglomerates of raw materials, thickeners, foaming agents and colored paints, the foaming metal 20 is produced when the mold is baked or melted in the mold 10 for a predetermined time.

Figure 4a is a perspective view showing a state of manufacturing a cooling and heating capacitor through the foamed metal product manufacturing method according to the present invention, Figure 4b is a perspective view showing a state of the cooling and heating capacitor manufactured by the manufacturing method of Figure 4a.

In the embodiment of FIGS. 4A and 4B, the pipe 50 is incorporated inside the molding die 10. After the raw materials, thickeners, foaming agents and coloring paints are added and then calcined and melted in the forming mold 10 for a predetermined time, a foamed metal mass 20 wrapped around the pipe 50 is generated to generate a cooling and heating capacitor. . Although only a cooling and cooling capacitor is shown in the drawings, it can be applied to various products such as heat exchangers and heat sinks by processing it for other purposes.

Figure 5a is a view showing a state including a nut in a structure through a method for manufacturing a foamed metal product according to the present invention, Figure 5b is a view showing a state in which the nut is integrally fastened to the structure by the manufacturing method of Figure 5a. to be.

5A and 5B, the nut 30 is fixed to the inside of the mold 10 through the fixing jig 32, and then the raw material, the thickener, the foaming agent, and the coloring paint are added to the mold 10. When the sintered and melted in a predetermined time, the structure (S) including the nut 30 is swelled in the space of the forming mold. At this time, the melting bolt 33 is coupled to the nut 30 to protrude to the outside of the molding die 10 and then fixed with a fixing jig 32 to prevent the nut 30 from moving during foaming. . Although only nuts are shown in the drawing, in addition, various products such as fixing pins, fixing plates, pipes, pipes, rods, and jigs are inserted into the molds and fixed with fixing jigs, and then raw materials, thickeners, foaming agents, and coloring paints are put into the molds. When foamed to form a structure in which a fixed pin, a fixed plate, a pipe, a pipe, a rod, JiG, etc. are integrally formed in the structure.

Figure 6a is a view showing a state of manufacturing the inner wall of the building using a foamed metal product according to the present invention, Figure 6b is a view showing a state in which the inner wall manufactured by the manufacturing method of Figure 6a is fastened to the wall surface of the building. .

6 is configured to form the inside of the mold 10 in the shape of a plate, as shown in Figure 6a, the bolt 60 is projected to the outside of the mold 10, the bolt 60 ) Is fixed to the fixing jig 32, and then the raw material, thickener, foaming agent and coloring paint are added to the inside of the mold 10 to bake and melt for a predetermined time. Become one.

Then, as shown in Figure 6b can be coupled to the wall (W) of the building using the bolt 60 and the nut (61).

Figure 6b is shown when used for the outer wall surface, when used as the interior material of the wall cut the predetermined volume including the plate 40 on the outer surface, so only the foamed metal 20 remains, it can be used as the interior material of the wall. In the case of FIG. 6, it is illustrated to be available only as an interior or exterior material of a building, but may be applied to various products in various forms according to other purposes and functions.

Figure 7a is a perspective view showing a state of manufacturing a door using a foamed metal product according to the present invention, Figure 7b is a perspective view showing a state of the door manufactured by the manufacturing method of Figure 7a.

In the embodiment of FIG. 7, as shown in FIG. 7A, the inner side of the forming die 10 is formed in a plate shape, and a cylindrical forming bundle 71 is formed on one side of the forming die 10. Protruding to the outside of the fixing jig (32) is fixed to the forming bundle (71), the other side is provided with a plate-shaped forming bundle 72 at the position where the hinge is coupled to the upper and lower. Thereafter, the raw material, the thickener, the foaming agent, and the coloring paint are introduced into the mold 10, and then the mold is baked and melted in the mold 10 for a predetermined time. On one side of the forming bundle 71, the forming bolt 75 for the latch bolt is protruded so that the latch bolt can be coupled.

As such, when the mold 10 and the mold bundles 71 and 72 are removed after the firing and melting, the door 70 as shown in FIG. 7B is formed. In this case, since the through hole 73 is formed at the portion from which the forming bundle 71 is removed, the handle may be used by combining the handle with the through hole 73. In addition, a latch bolt hole 76 is formed in communication with the through hole 73 is coupled to the latch bolt hole 76, the latch bolt is a component of the handle.

On the other hand, since the recessed portion 74 is formed in the portion from which the forming bundle 72 is removed on the other side of the through hole 73, a hinge (not shown) is used to couple the recessed portion 74.

In the case of FIG. 7, the door is used only as a door used in a building. However, the present invention may be applied to various products in various forms according to other purposes and functions.

Hereinafter, an embodiment of the raw material, the thickener, the foaming agent, and the coloring paint will be described through the method of manufacturing the foamed metal product as described above.

<Example 1>

900 g of aluminum as a raw material, 30 g of sodium as a thickener, 40 g of ZrH2 as a blowing agent, and 30 g of cobalt as a coloring paint were pulverized, and then agitated powder or a mass of a press was put into a mold. After firing and melting at a predetermined temperature of 700 degrees, foaming, cooling, and removing the mold, a foamed aluminum metal mass was produced.

The foamed aluminum ingot manufactured by the above method has a porosity of 90% or more, and thus, a homogeneous product production and production efficiency are improved by 30% or more as compared to the foamed aluminum ingot manufactured accordingly.

<Example 2>

900g of aluminum waste material as raw material, 35g of Ca as thickener, 55g of ZrH2 as blowing agent, 10g of cobalt as coloring paint was pulverized, and then agitated powder or a lump was put into a molding machine. Thereafter, after firing and melting at a predetermined time of 750 degrees, the foam was cooled and cooled, and then the mold was removed to produce a foamed metal mass.

The foamed metal ingot produced by the above method has a porosity of 95% or more, and thus, a homogeneous product production and production efficiency are improved by 35% or more compared with the conventionally manufactured foamed metal ingot.

The reason why the coloring paint is less than the above-mentioned Example 1 is that it contains less because the coloring paint is already contained in the aluminum waste material.

Embodiment of the method for producing a foamed metal product of the present invention described above is merely illustrative, and those skilled in the art to which the present invention pertains that various modifications and equivalent other embodiments are possible. You can see well. Therefore, it will be understood that the present invention is not limited to the forms mentioned in the above detailed description. Therefore, the true technical protection scope of the present invention will be defined by the technical spirit of the appended claims. It is also to be understood that the present invention includes all modifications, equivalents and substitutions within the spirit and scope of the invention as defined by the appended claims.

[Description of the code]

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 bundle

73: through hole

74: recess

75: forming bolt for latch bolt

76: Latch Bolt Hole

Claims (7)

1. Grinding the raw material made of any one of aluminum, aluminum waste material, and alloy to form a powder (S10);

   Stirring the powder raw material, thickener, foaming agent, and coloring paint (S20);

   Pressing the powder into lumps of a predetermined size (S30);

   Fixing the structure inside the mold 10 (S40);

   Injecting powder or agglomerates into the mold 10 (S50);

   Firing and melting the powder or agglomerates and molding the powder or agglomerates according to the shape of the mold 10 (S60);

   Cooling the mold 10 by air or water cooling (S70) and

   Method of producing a foamed metal product, characterized in that it comprises the step (S80) of removing the molding die (10).
2. The method of claim 1,

   The raw materials, thickeners, foaming agents and coloring paints,

   Raw material 86 to 96% by weight, thickener 1 to 6% by weight, foaming agent 1 to 10% by weight, 1-8% by weight of the coloring paint, characterized in that the foamed metal product manufacturing method.
3. The method according to claim 1 or 2,

   The raw material,

   Foamed metal product manufacturing method characterized in that it further comprises a ceramic.
4. The method according to claim 1 or 2,

   The thickener,

   Method for producing a foamed metal product, characterized in that any one or two or more of calcium, sodium, nitrogen, oxygen, carbon dioxide, water, argon are mixed.
5. The method according to claim 1 or 2,

   The blowing agent,

   TiH2, ZrH2, polyvinyl alcohol, polyurethane, polyvinyl acetate, phenol resin, cellulose, sodium phosphate, sodium chloride, calcium chloride, sodium acetate, ferric chloride, foamed metal products characterized in that at least two or more are mixed Manufacturing method.
6. The method according to claim 1 or 2,

   The coloring paint,

   Calcium hydroxide, zinc, silicon, carbon dioxide, ArH2, Na2, Co3, iron, cobalt, manganese, nickel, copper any one or two or more methods of producing a foamed metal product, characterized in that the mixture.
7. A foamed metal product comprising any one of foamed metal ingots, bolts, nuts, JIG, rods, plates, pipes, pipes, fixing pins, and doors by the method of claim 1.

Images