WO2016200913A1 - Procédé de fabrication d'un fil électrique à haut rendement - Google Patents

Procédé de fabrication d'un fil électrique à haut rendement Download PDF

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Publication number
WO2016200913A1
WO2016200913A1 PCT/US2016/036413 US2016036413W WO2016200913A1 WO 2016200913 A1 WO2016200913 A1 WO 2016200913A1 US 2016036413 W US2016036413 W US 2016036413W WO 2016200913 A1 WO2016200913 A1 WO 2016200913A1
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WO
WIPO (PCT)
Prior art keywords
brass
copper
kilograms
mixture
pounds
Prior art date
Application number
PCT/US2016/036413
Other languages
English (en)
Inventor
John M. Bourque
Original Assignee
Bourque Industries, 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
Priority claimed from US15/069,172 external-priority patent/US20160265087A1/en
Application filed by Bourque Industries, Inc. filed Critical Bourque Industries, Inc.
Priority to US15/110,535 priority Critical patent/US20170157665A1/en
Publication of WO2016200913A1 publication Critical patent/WO2016200913A1/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C9/00—Alloys based on copper
    • C22C9/04—Alloys based on copper with zinc as the next major constituent
    • 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
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/14—Treatment of metallic powder
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/04—Making non-ferrous alloys by powder metallurgy
    • C22C1/0425—Copper-based alloys
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/10—Alloys containing non-metals
    • C22C1/1084—Alloys containing non-metals by mechanical alloying (blending, milling)
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C26/00—Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
    • C22C32/0089—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with other, not previously mentioned inorganic compounds as the main non-metallic constituent, e.g. sulfides, glass
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
    • H01B1/02—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
    • H01B1/026—Alloys based on copper
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C26/00—Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes
    • C22C2026/002—Carbon nanotubes

Definitions

  • This application relates generally to electrically conductive wire. More specifically, this application relates to wire fabricated from a new metallic mixture employing carbon nanotubes.
  • Electrical wire is a basic, integral part of modern electrical infrastructure. Electrical wire brings electricity to homes and places of business and within those units, connects a myriad of electrical appliances to produce all the functions of modern life.
  • Electrical wiring varies by composition, width and other parameters and is selected based on the desired use, the amount of current to be delivered, etc.
  • copper has been the chosen conductor, although other metals including but not limited to aluminum, silver, and gold also are excellent conductors.
  • Highly purified copper has been the best conductor.
  • adding 200 - 400 ppm of oxygen has been known to improve copper conductivity because the oxygen combines with impurities to form oxides, which are precipitates from the rest of the copper. If the impurities are not precipitated, they interfere with the copper conductivity.
  • a method of treating a material can comprise: (a) adding a solvent to a high-speed blender; (b) concurrent with or following step (a), adding brass granules to the blender and blending at high speed until mixed; (c) concurrent with or following step (a), adding copper granules to the blender and blending at high speed until mixed; (d) concurrent with or following step (a), adding carbon nanotubes (CNT) to the blender and blending until mixed; (e) mixing a solution produced by steps (b)-(d), which solution excludes silver, iron pyrite, and graphene, into an additional mixture of brass and copper granules and mixing until all of the additional mixture of brass and copper granules are uniformly saturated with the solution; and (f) drying the mixture of step (e) to a dry powder thereby forming a treated material.
  • Clause 2 The method of clause 1 can further include (g) mixing the treated material with one or more metals in a high-temperature crucible and heating until melted thereby forming a metal alloy, wherein each of the one or more metals is a ferrous and/or nonferrous metal.
  • Clause 3 The method of clause 1 or 2 can further include (h) pouring the melted metal alloy of step (g) into a mold and allowing the poured melted metal alloy to cool and harden.
  • Clause 4 The method of any of clauses 1-3 can further include (i) forming the cooled and hardened metal alloy into a finished form via one of the following processes: drawing through a die; or continuous casting; or rolling.
  • Clause 5 The method of any of clauses 1-4, wherein at least one of the brass and copper granules can be passed through 100 mesh.
  • Clause 6 The method of any of clauses 1-5, wherein the solvent can be acetone.
  • Clause 7 The method of any of clauses 1-6, wherein, in steps (a) and (b), 1.9 liters - 3.79 liters (1 ⁇ 2 gallon - 1 gallon) of acetone and 0.45 kilograms - 0.91 kilograms (1 pound - 2 pounds) of brass granules can be added to the blender.
  • Clause 8 The method of any of clauses 1-7, wherein, in step (c), 0.45 kilograms - 0.91 kilograms (1 pound - 2 pounds) of copper granules can be added to the blender.
  • Clause 9 The method of any of clauses 1-8, wherein each instance of blending can be repeated for five minute periods.
  • Clause 10 The method of any of clauses 1-9, wherein, in step (d), 1 - 2 grams of carbon nanotubes (CNT) can be added to the acetone-brass-copper mixture.
  • CNT carbon nanotubes
  • Clause 11 The method of any of clauses 1-10, wherein one or the one or more metals can be copper or aluminum.
  • Clause 12 The method of any of clauses 1-11, wherein in step (e) the mixture of brass and copper can be a 1:1 ratio of brass and copper.
  • Clause 13 The method of any of clauses 1-12, wherein the mixture of brass and copper can comprise 9.1 kilograms - 13.6 kilograms (20 pounds - 30 pounds) of each.
  • Clause 14 The method of any of clauses 1-13, wherein 3.6 kilograms - 9.1 kilograms (8 pounds - 20 pounds) of the treated material can be added to 41 kilograms - 54.4 kilograms (90 pounds - 120 pounds) of the one or more metals.
  • Clause 15 The method of any of clauses 1 -14, wherein 5 kilograms - 5.9 kilograms (11 pounds - 13 pounds) of treated material can be added to 41 kilograms - 54.4 kilograms (90 pounds - 120 pounds) of the one or more metals.
  • Clause 16 The method of any of clauses 1-15, wherein steps (b)-(d) can be performed in any order to produce the solution.
  • Clause 17 The method of any of clauses 1-16, wherein any two or more of steps (a)- (d) can be combined to produce the solution.
  • a method of treating a material can comprise: (a) mixing solvent, brass granules, copper granules, and carbon nanotubes in the absence of silver, iron pyrite, and graphene; (b) adding the mixture of step (a) to an additional mixture of brass and copper granules and mixing until all of the granules of the additional mixture of brass and copper are uniformly saturated with the mixture of step (a); and (c) drying the mixture of step (b) to a powder to form a treated material.
  • Clause 19 The method of clause 18 can further include mixing the treated material with one or more ferrous and/or nonferrous metal(s) in a high temperature crucible and heating until melted.
  • Clause 20 The method of clause 18 or 19, wherein step (a) can include mixing in a blender.
  • a method of treating a material includes mixing solvent, brass granules, copper granules, and carbon nanotubes, in the absence of silver, iron pyrite, and graphene, to form a first mixture.
  • the first mixture is then added to a second mixture of brass and copper granules.
  • the first and second mixtures are mixed until all of the granules of the second mixture of brass and copper are uniformly saturated with the first mixture, whereafter the second mixture is dried to form a treated material.
  • Clause 22 The method of clause 21 , wherein the treated material can be mixed with one or more metals in a high- temperature crucible and heated until melted to form a metal alloy. Each of the one or more metals can be a ferrous and/or nonferrous metal.
  • Clause 23 The method of clause 21 or 22 can further include pouring the melted metal alloy into a mold and allowing the poured melted metal alloy to cool and harden.
  • Clause 24 The method of any of clauses 21-23 can further include forming the cooled and hardened metal alloy into a finished form via one of the following processes: drawing through a die; or continuous casting; or rolling.
  • Fig. 1 is a diagram illustrating a process for making an example treating wash.
  • FIGs. 2A and 2B are diagrams illustrating front and top views of a ballistic strike plate assembly according to another aspect of the present invention.
  • FIGs. 3A and 3B are diagrams illustrating a ballistic strike plate assembly according to another aspect of the present invention.
  • FIGs. 4A and 4B are diagrams illustrating a ballistic strike plate assembly according to another aspect of the present invention.
  • Fig. 5 is a schematic of the heat sink with a high-wattage LED light source which is also an exemplary heat source;
  • FIGs. 6A and 6B are perspective views (6B in partial cross-section) of one example heat sink
  • FIGs. 7A and 7B are perspective views (7B in partial cross-section) of the example heat sink shown in Figs. 6 A and 6B;
  • FIGs. 8A, 8B and 8C are schematics illustrating heat transfer from the LED back plate to the heat sink by surface mounting (Fig. 8A), pocket mounting (Fig. 8B) and encasement mounting (Fig. 8C);
  • Fig.9 is a perspective view of another example heat sink with numerous separated pins to dissipate heat
  • Figs. 10A and 10B are perspective views of another example heat sink;
  • Fig. 10A is a perspective view of the heat sink with the heat source embedded in a circular area.
  • Fig. 10B is a cross-sectional perspective view of the heat sink with the heat source shown at the bottom with multiple fins to dissipate heat;
  • Figs. 11 A, 11B and 11C show top, side, and cross-sectional views of another exemplary heat sink.
  • Figs. 12 and 13 are diagrams illustrating processes for making example treated materials, each of which can be mixed with any ferrous and/or nonferrous metal or combinations of ferrous and/or nonferrous metals (alloys) on the periodic table of the elements to form a metal or alloy having improved properties, especially improved electrical and thermal conductance and hardness.
  • the present invention relates to solid-material compositions having enhanced physical and electrical properties as well as products formed using the material and methods for making the material and the products.
  • One aspect of the present invention includes a wash or bath employed to treat ingredients used to form the ballistic strike plates and assemblies according to the present invention. Since the volume of the wash or bath will vary with the particular application, an illustrative example is given for formulating the wash using one gallon of acetone. Persons skilled in the art will appreciate that the amounts of the ingredients disclosed in the example can be linearly scaled to formulate larger or smaller batches of the wash.
  • brass is mixed with acetone in a commercial blender.
  • about 454 grams of brass (about 100 mesh or finer) is mixed with one gallon of acetone in a commercial blender at high speed for about 10 minutes or until a gold color appears at the surface of the acetone when the blender is stopped.
  • about 2 grams of silver granules are added and mixed.
  • carbon nanotube material is added and mixed.
  • about one gram of multi -walled carbon nanotube material is added and mixed at high speed for about 5 minutes.
  • iron pyrite is added and mixed.
  • the liquid is strained and may be used as a wash or bath. All of the strained solid matter (herein "the first example treated material") may be stored for further use as disclosed herein. Once materials are processed, the wash liquid used may be collected and recycled by adding it to new batches of the wash liquid.
  • wash liquid is formulated, constituent materials of products to be fabricated are washed using it. A sticky film merges with the constituent materials. The constituent materials are bonded together by drying and application of pressure, either in an oven or at room temperature.
  • ballistic strike plates formed from a special aluminum alloy are advantageously employed in armor assemblies, especially body armor assemblies. Since the amount of alloy needed to form plates of particular dimensions will vary with sizes of the plates needed for the particular application, an illustrative example is given for formulating a kilogram of the alloy. Persons skilled in the art will appreciate that the amounts of the ingredients disclosed in the example can be linearly scaled to formulate larger or smaller amounts of the aluminum alloy.
  • special aluminum alloy For a total weight of about 1 Kg of special aluminum alloy, about 130 grams of the first example treated material as described above and about 10 grams of silver powder are melted into about 860 grams of aluminum.
  • the aluminum alloy formulated according to the present invention as just described is referred to herein as "special aluminum alloy.”
  • the ballistic strike plates of the present invention may be formed by hot rolling ingots of the special aluminum alloy or may be formed by casting from the molten alloy.
  • the ballistic strike plates of the present invention may be formed by hot rolling ingots of aluminum or other aluminum alloys or may be formed by casting from molten aluminum or other aluminum alloys but are believed to have a lower strength than the special aluminum alloy. Thickness of the finished ballistic strike plates will vary according to the particular application; for body armor the plates may be about 0.0625 inch to about 0.250 inch thick, depending on the threat level they are designed to meet. For vehicle or structure armor the ballistic strike plates may have a thickness of up to an inch or greater, depending on the threat level they are designed to meet.
  • Fig. 2A shows a front view of a ballistic strike plate assembly according to the present invention.
  • Fig. 2B shows an illustrative top view of strike plate assembly 20. While the illustrative bottom view shown in Fig. 2A indicates that plate 20 is curved, persons of ordinary skill in the art will appreciate that plate 90 may be formed flat, depending on the application.
  • body-armor vests are sometimes constructed by supplying a vest made from a fabric material. The vests contain pockets into which ballistic strike plates or plate assemblies are inserted.
  • the ballistic strike plate assemblies according to the present invention include assemblies formed in this manner and configured to be inserted into the pockets of such fabric vests.
  • FIGs. 3A and 3B diagrams illustrate a cross-sectional view and a face view, respectively, of a ballistic strike plate assembly 30 according to another aspect of the present invention.
  • An illustrative ballistic plate assembly according to the present invention is formed using a special aluminum alloy plate 32 made according to the present invention.
  • plate 32 may have a thickness of about 0.125 inches.
  • a grade II titanium plate 34 such as a 0.125 inch thick plate CAS 7440-32-6 available from Allegheny Ludlum Corp., of Brackenridge, Pa. is also used. While in the present example the two plates have the same thickness, this is not necessary for practicing the present invention. Persons of ordinary skill in the art will recognize that the thicknesses of plates 32 and 34 will be selected according to the threat level to which the ballistic strike plate assembly will be designed to encounter.
  • a sheet of ballistic gap foam 36 having a thickness of about 0.125 inches in an illustrative embodiment, having adhesive disposed on both surfaces, such as model DMG-FM- 004, manufactured by DMG, a division of Hisco, of Tempe Ariz., is adhered to a first surface of one of the plates. A first surface of the other plate is adhered to the other surface of the foam sheet 36.
  • a ballistic fabric plate 38 is made using multiple layers of a ballistic fabric such as Spectra II available from Honeywell of Colonial Heights, Va.
  • a first stack of a plurality of layers of such fabric is placed over the stack and a second stack of a plurality of layers of such fabric are placed over the titanium sheet.
  • a second stack of a plurality of layers of such fabric are placed over the titanium sheet.
  • fifty sheets are employed in the first and second stacks. The assembled stacks are then heated to about 275.degree. F.
  • the ballistic fabric plate is adhered to the exposed second surface of the aluminum plate 32 using a double-sided adhesive tape 42, such as 3M-VHB 4950, available from 3M Corporation of St. Paul, Minn.
  • a double-sided adhesive tape 42 such as 3M-VHB 4950, available from 3M Corporation of St. Paul, Minn.
  • the ballistic plate assembly 30 is then covered with a first sheet 44 of ballistic wrap such as M-7 Spall System Nylon PSA from DMG a division of Hisco of Tempe Ariz.
  • the first sheet 44 of ballistic wrap is held in place by a layer of adhesive 46.
  • the edges 48 of the first sheet of ballistic wrap 44 are folded over the four edges of the assembly.
  • a second smaller sheet of ballistic wrap 50 is placed over the portion of the second surface of the aluminum plate not covered by the folded over edges of the first sheet of ballistic wrap.
  • the second sheet 50 of ballistic wrap is also held in place by a layer of adhesive 46.
  • the titanium face of the assembly faces outward towards the threat.
  • FIGs. 4A and 4B diagrams illustrate a cross-sectional view and a face view, respectively, of a body-armor plate assembly according to another aspect of the present invention.
  • an armor plate assembly 60 is formed using a special aluminum alloy plate 62 made according to the teachings of the present invention.
  • plate 22 may have a thickness of about 0.125 inches.
  • a grade II titanium plate 64 such as a 0.125 inch thick plate CAS 7440-32-6 available from Allegheny Ludlum Corp., of Brackenridge, Pa. While in the present example the two plates have the same thickness, this is not necessary for practicing the present invention. Persons of ordinary skill in the art will recognize that the thicknesses of plates 62 and 64 will be selected according to the threat level to which the ballistic strike plate assembly will be designed to encounter.
  • a first surface of a sheet of ballistic gap foam 66 having a thickness of about 0.125 inches in an illustrative embodiment, having adhesive disposed on both faces, such as model DMG-FM-004, manufactured by DMG, a division of HISCO, of Tempe Ariz., is adhered to a first surface of one of the plates 62 and 64. A first surface of the other plate is adhered to the other surface of the foam sheet 66.
  • a ballistic backing plate 68 is made using multiple layers of a ballistic fabric such as Spectra II available from Honeywell of Colonial Heights, Va.
  • a stack is assembled from a plurality of layers of such fabric.
  • a sheet 70 formed from a material such as a titanium sheet, having a thickness of about 0.05 inches in an illustrative embodiment, such as a CAS 7440-32-6 plate from Allegheny Ludlum Corp. of Brackenridge, Pa. is placed over the stack and a second stack of a plurality of layers of such fabric are placed over the titanium sheet.
  • fifty sheets are employed in the first and second stacks. The assembled stacks are then heated to about 275. degree. F.
  • ballistic fabric plate 68 is adhered to the exposed second surface of the aluminum plate 62 using a double sided adhesive tape, such as 3M-VHB 4950, available from 3M Corporation of St. Paul, Minn.
  • the ballistic plate assembly 60 is then covered with a first sheet 74 of ballistic wrap such as M-7 Spall System Nylon PSA from DMG a division of Hisco of Tempe Ariz.
  • the first sheet 74 of ballistic wrap is held in place by a layer of adhesive 76.
  • the edges 78 of the first sheet of ballistic wrap 74 are folded over the four edges of the assembly.
  • a second smaller sheet of ballistic wrap 80 is placed over the portion of the second surface of the aluminum plate not covered by the folded over edges of the first sheet of ballistic wrap.
  • the second sheet 80 of ballistic wrap is also held in place by a layer of adhesive 76.
  • the titanium face of the assembly faces outward towards the threat.
  • a coating 82 for example an elastomeric coating such as Plasti-Dip coating from Plasti-Dip International of Blaine, Minn., is formed over the seams 84 made by the intersection of the edges of folded-over portions 78 of the first sheet of ballistic wrap layer 74 and at the outer edges 86 of the second sheet 80 of the ballistic wrap.
  • a second example treated material is disclosed hereafter that can be mixed with any ferrous or nonferrous metal or combination of two or more ferrous and/or nonferrous metals on the periodic table of the elements to form a metal or metal alloy having improved properties, especially improved electrical and thermal conductance and hardness.
  • An example target application for this new metal or alloy is a heat sink for a 255 Watt LED light source that outputs 25,000 lumens of light without using fans. Requirements for this LED light source included operation temperatures less than 85°C for prolonged intervals of time (e.g., overnight) without causing thermal damage to the LED light source. Another requirement was no moving parts or mechanisms requiring external supervision or maintenance, because failure to such moving parts would cause failure of the LED light source. The LED light source by itself should also be able to stay operational for over 20 years without maintenance.
  • heat sinks are passive heat exchangers that cool an attached or adjacent heat source, such as an LED light source by dissipating heat into the surrounding medium.
  • the performance of a heat sink is affected by the material(s) and properties of the materials forming the heat sink, the mass of the material, and the surface area available for heat exchange with a cooler medium than the heat source.
  • a heat sink for an LED light source can optionally be accompanied by a fan for faster dispersion of heat therefrom.
  • the example heat sink 1 includes a base plate 7 that abuts the LED light source 2 (i.e., a single LED or multiple LEDs).
  • LED light source 2 can have a base plate 6 to provide a surface for heat transfer to heat sink base plate 7.
  • Thermal paste or other greases 5 can be optionally used to improve heat transfer between abutting surfaces of base plates 6 and 7.
  • Base plate 7 can have various shaped fins extending from base plate 7 that serve to provide surface area for heat exchange to ambient air 3 surrounding heat sink 1. Heating of air 9 adjacent fins 8 of heat sink 1 induces a natural conduction generating air flow cooling heat sink. Operation of the heat sinks 1, 101 (Figs. 6A-7A) requires airflow 3, 9.
  • FIGs. 6A-11C Designs for heat sink 1 are presented in Figs. 6A-11C.
  • the design of heat sink 101 is governed by the same principles used for heat sink 1. It is believed that when used to make parts of a heat sink, such as fins 8, the new metal or alloy formed using the second example treated material (discussed hereinafter) can improve the efficiency of heat exchange, allowing the heat sink to handle cooling of higher heat-generating sources, such as LED light source 2.
  • the mass of a base plate 107 of heat sink 101 is selected to handle the wattage of LED light source 2. However, this mass is less than what would be required by heat sinks made from the prior art metals or alloys.
  • the shape of the base plate 107 shown in Figs. 6A-7B was made collinearly bell shape (shown best in Fig. 7B) to focus the mass directly behind the LED light source 2 to absorb heat efficiently.
  • any shape can be used for base plate 107 made from the new metal or alloy.
  • the thermal mass of base plate 107 must still stay below a given saturated equilibrium, where it can no longer absorb additional heat from the LED light source 2.
  • Fins 108 made from the new metal or alloy stay cooler and are more effective exchanging heat with air than fins 108 made from prior art metals or alloys.
  • fins 108 can be modularly attached to the base plate 107 to allow for ease of trying different fin designs.
  • fins 108 can be directly cast with base plate 107.
  • Heat sink 101 can optionally include an upper attachment 111 and/or a lower attachment 112 to assemble fins 108 to base plate 107 and to provide additional cooling surface area.
  • Heat source 101 can include additional structures (not shown), such as a focusing lens for LED light source 2 and/or structural mounting components for supporting heat sink 101 for use.
  • various materials 6 can be inserted between base plate 6, 106 and base plate 7, 107 including, but not limited to, grease, insulating mica washer, thermally conductive tape, epoxy, wire-form Z clips, standoff spacers, push pins with expandable ends, and flat sprig clips. These materials can optimize thermal conductivity between base plate 6, 106 and base plate 7, 107, which may not have perfectly even surfaces for maximal heat transfer.
  • CNT carbon nanotubes
  • graphene are used to form the new metal or alloy. It has been observed that the addition of small amounts of CNT and graphene to a ferrous and/or nonferrous metal, and/or a combination of ferrous and/or nonferrous metals results in higher heat conductivity in the resulting metal or alloy. In an example, two attempts to measure thermal conductivity of the new metal or alloy formed with CNT and graphene exceeded the heat conductivity measurable on equipment routinely used to measure heat conductivity. CNT ( single- or multiple-walled carbon nanotubes) and graphene are available from many commercial sources.
  • the second example treated material can be mixed with one or more of the following to form one example of the new metal or alloy: aluminum (new or recycled), copper, tungsten, carbide, silver, steel, lead, and combinations thereof.
  • the thus formed new metal or alloy can be used in a variety of composites including, for example, beryllium oxide in a beryllium matrix.
  • the new metal or alloy can also be utilized with diamonds, and/or silicon carbide in aluminum matrix, for example, a matrix of diamond in a copper-silver matrix, and plastics.
  • fin 8, 108 arrangements were tested, including straight and curved fins that were removably attached, or molded into the heat sink.
  • fins are cross-cut at regular intervals to enable more air flow.
  • the heat sink design described herein must be weighted under the heat source more than typical designs. Larger lateral projections were not as successful.
  • the second example treated material can be used with any ferrous and/or nonferrous metal or combination of metals on the periodic table of the elements, including, without limitation, aluminum (new or recycled), copper, steel, lead, and combinations thereof.
  • the second example treated material can also be utilized to treat nonmetallic materials, such as plastic.
  • brass is mixed with acetone in a commercial blender.
  • about 454 grams (1 pound) of brass granules (in an example, 100 mesh or finer) is mixed with about 1.9 liters (0.5 gallons) of acetone in a commercial blender at high speed until a gold color appears at the surface of the acetone when the blender is stopped.
  • the brass granules and acetone were mixed in about five-minute increments until the gold color appeared at the surface of the acetone. This mixing produces an acetone-brass (AB) combination.
  • CNT carbon nanotube
  • the ABCG-CNT combination is mixed with a mixture of brass and copper granules (in an example, each of which is 100 mesh or finer).
  • the mixture of brass and copper granules of step 218 is a 50/50 or 1:1 mixture of brass and copper granules.
  • the 50/50 mixture of brass and granules includes, for example, about 11.3 kilograms (25 pounds) of brass and about 11.3 kilograms (25 pounds of copper) to produce an ABCG25-CNT mixture that is mixed for about ten minutes and/or until all the materials are uniformly saturated.
  • ABCG25-CNT combination is fully dried to form an ABCG25-CNT powder that is free of residual solvent.
  • This ABCG25-CNT powder is the second example treated material.
  • the thus prepared second example treated material can be mixed with any ferrous or nonferrous metal, or combinations of ferrous and/or nonferrous metals of the periodic table of the elements in a high-temperature crucible with induction heater for casting metals.
  • ferrous or nonferrous metal or “combinations of ferrous and/or nonferrous metals” will be individually or collectively referred to as “the ferrous and/or nonferrous metal(s)”.
  • ferrous and/or nonferrous metal(s) can be the same or different from those in the second example treated material.
  • the second example treated material can be added at the start of melting the ferrous and/or nonferrous metal(s) prior to casting.
  • the second example treatment material can be added to the ferrous and/or nonferrous metal(s) at any time.
  • a ratio of the second example treated material to the ferrous and/or nonferrous metal(s) can be about 5 kilograms-5.9 kilograms (llpounds-13 pounds) of the second example treated material to 41 kilograms-54.4 kilograms (90 pounds-120 pounds) of the ferrous and/or nonferrous metal(s).
  • the transition of the ferrous and/or nonferrous metal(s) mixed with the second example treated material required a higher temperature than normally used for said ferrous and/or nonferrous metal(s) not mixed with the second example treated material and was in the range of about 815°C to 1538°C (1500°F to 2800°F), depending on the ferrous and/or nonferrous metal(s) used.
  • degassing means were utilized during mixing of the second example treated material with the ferrous and/or nonferrous metal(s) to ensure safety.
  • acetone was used as a solvent.
  • suitable solvents include polar or nonpolar solvents.
  • polar solvents include water, acetone, alcohol, dimethylformamide, n-methyl-2-pyrrolidone, dichloroethylene, or chloroform.
  • steps 210 and 212 The times, weights, and ratios of the weights given above are examples for the purpose of illustration only and may be varied by one skilled in the art to obtain desired results.
  • the solvent can vary from about 1.9 liters-7.6 liters (0.5 gallon-2 gallons).
  • CNT can be varied from 0.5 grams-10 grams, in an example from 0.6 grams-5 grams, in another example from 0.8 grams-2 grams.
  • the order of steps 210-218 can be varied by one skilled in the art and/or steps 210-218 can be combined as necessary for convenience.
  • the brass and copper granules of steps 210-212 may be added to the acetone in the blender at the same time.
  • the ABC25G-CNT powder can be optionally filtered after being dried.
  • the weights of brass and copper discussed above in connection with step 218 were chosen for effectiveness as well as convenience with the available equipment and can be varied depending on desired parameters as well as sizes of mixing containers.
  • the weight of each of brass and copper in step 218 can range from 6.8 kilograms-22.6 kilograms (15 pounds-50 pounds), in another example between about 9.1 kilograms- 15.9 kilograms (20 pounds-35 pounds), and in another example between about 10 kilograms- 13.6 kilograms (22 pounds-30 pounds).
  • the amount of the second example treated material namely, the ABCG25-CNT powder can be varied when added to the ferrous and/or nonferrous metal(s). Accordingly, the foregoing examples including weights and/or ratio of weights and mixing times are not to be construed in a limiting sense but only as examples of forming the second example treated material and using the second example treated material to form the treated metal or alloy.
  • ferrous and/or nonferrous metal(s) Before or during the melting of the ferrous and/or nonferrous metal(s) in the casting operation, other additives can be added, such as, in an example, metallic alloys, plastic, cloth, or any combination thereof.
  • other additives can be added, such as, in an example, metallic alloys, plastic, cloth, or any combination thereof.
  • the second example treated material enables the material being treated, for example, the ferrous and/or nonferrous metal(s), to achieve greater electrical and mechanical properties than said ferrous and/or nonferrous metal(s) would achieve without the second example treated material. It is also believed that one or more of the following properties of ferrous and/or nonferrous metal(s) mixed with the second example treated material are improved by use of the second example treated material in the manner discussed above: thermal conductance, electrical conductance, hardness, and resistance to microwaves.
  • the second example treated material and/or the ferrous and/or nonferrous metal(s) treated with the second example treated material can be part of a coating that can be applied in any suitable and/or desirable manner to other materials such as metal, plastic, cloth, etc. to form a coating on said other materials.
  • ferrous and/or nonferrous metal(s) treated with the second example treated material is electrical wire.
  • the ferrous and/or nonferrous metal(s) treated with the second example treated material can be used to make electrical wire grade copper or aluminum.
  • a third example treated material is described hereafter that can be mixed with any ferrous or nonferrous metal or combination of two or more ferrous and/or nonferrous metals on the periodic table of the elements to form a metal or metal alloy having improved properties, especially improved electrical conductivity.
  • An example target application for this new metal or alloy is electrical wire used to conduct electricity.
  • the third example treated material can be mixed with one or more of the following to form one example of the new metal or alloy: aluminum (new or recycled), copper, tungsten, silver, brass, steel, lead, and combinations thereof.
  • the thus formed new metal or alloy can be used in a variety of composites, including, for example, beryllium oxide in a beryllium matrix.
  • the new metal or alloy can also be utilized with diamonds, and/or silicon carbide in an aluminum matrix, for example, a matrix of diamond in a copper-silver matrix, and plastics.
  • Brass is known to be an alloy of copper and zinc. It is available in a wide range of ratios. In an example, brass can have a copper range of 50-97% and a zinc range of 3-50%. Brass is known for its low friction and high workability. In an example it can be strengthened with aluminum to form a highly beneficial hard layer of aluminum oxide. Adding iron, aluminum, silicon, and manganese to brass makes it more durable. The copper in brass makes brass germicidal, so microbial damage to the new metal or alloy formed with the third example treated material described hereinafter is avoided.
  • the third example treated material can be used with any ferrous and/or nonferrous metal or combination of metals on the periodic table of the elements, including, without limitation, aluminum (new or recycled), copper, steel, lead, and combinations thereof.
  • the third example treated material can also or alternatively be utilized to treat non-metallic materials, such as plastic.
  • the new metal or alloy formed with the third example treated material can be used with other host metals that are at least minimally electrically conductive, as well as on some non-metallic materials, such as, without limitation, plastics, rubber, fabric, and paper.
  • brass is mixed with acetone in a commercial blender.
  • about 454 grams (1 pound) of brass granules (in an example, 100 mesh or finer) is mixed with about 3.8 liters (1.0 gallons) of acetone in a commercial blender at high speed until a gold color appears at the surface of the acetone when the blender is stopped.
  • the brass granules and acetone were mixed in about 5 minute increments until the gold color appeared at the surface of the acetone.
  • This mixing produced an acetone-brass (AB) combination.
  • about 454 grams (1 pound) of copper granules (in an example, 100 mesh or finer) are added to the AB combination and mixed for about 5 minutes to ensure complete mixing. This produced an ABC combination.
  • step 316 about 1 gram of carbon nanotube (CNT) material is added to the ABC combination in the blender to form an ABC-CNT mixture.
  • This ABC-CNT mixture was mixed for about 5 minutes producing an ABC-CNT combination.
  • the ABC-CNT combination is mixed with a mixture of brass and copper granules (in an example, each of which is 100 mesh or finer).
  • the mixture of brass and copper granules of step 316 is a 50/50 or 1:1 mixture of brass and copper granules.
  • the 50/50 mixture of brass and granules includes, for example, about 11.3 kilograms (25 pounds) of brass and about 11.3 kilograms (25 pounds) of copper to produce an ABC25-CNT mixture that is mixed for about 10 minutes and/or until all the materials are uniformly saturated.
  • the thus prepared third example treated material can be mixed with any ferrous or nonferrous metal, or combinations of ferrous and/or nonferrous metals of the periodic table of the elements in a high-temperature crucible with induction heater for casting metals.
  • ferrous or nonferrous metals or “combinations of ferrous and/or nonferrous metals” will be individually or collectively referred to as “the ferrous and/or nonferrous metal(s)”.
  • ferrous and/or nonferrous metal(s) can be the same or different from those in the first or second example treated materials described above.
  • the third example treated material can be added at the start of melting the ferrous and/or nonferrous metal(s) prior to casting.
  • the third example treated material can be added to the ferrous and/or nonferrous metal(s) at any time.
  • the third example treated material is prepared without the use of silver and iron pyrite, used to prepare the first example treated material, and without graphene used to prepare the third example treated material. Accordingly, the third example treated material is distinguishable over the first and second example treated materials by the absence of silver, iron pyrite, and graphene.
  • a ratio of the third example treated material to the ferrous and/or nonferrous metal(s) can be about 5 kilograms-5.9 kilograms (11 pounds- 13 pounds) of the third example treated material to 41 kilograms-54.4 kilograms (90 pounds- 120 pounds) of the ferrous and/or nonferrous metal(s).
  • the transition of the ferrous and/or nonferrous metal(s) mixed with the third example treated material required a higher temperature than normally used for said ferrous and/or nonferrous metal(s) not mixed with the third example treated material and was in the range of about 815°C to 1538°C (1500°F to 2800°F), depending on the ferrous and/or nonferrous metal(s) used.
  • degassing means were utilized during mixing of the third example treated material with the ferrous and/or nonferrous metal(s) to ensure safety.
  • the mixture was poured into long narrow molds where it was allowed to cool, after which it was drawn to make narrow gauge wires.
  • the drawing process can be done with polycrystalline dyes or natural single crystal diamond dyes.
  • the cool, molded mixture can be formed utilizing a continuous casting and rolling process.
  • the dust formed narrow gauge wires exhibited a hardness of 85 on the Rockwell Scale versus a hardness of 110 for a spherical copper sample.
  • various materials can be used to coat the thus formed wires, including, in an example, grease, an insulating mica washer, thermally conductive tape, epoxy, wire-form Z clips, standoff spacers, push pins with expandable ends, and flat spring clips. These devices and materials optimize the junction of the wire and connections with other devices.
  • acetone was used as a solvent.
  • suitable solvents include polar or nonpolar solvents.
  • polar solvents include water, acetone, alcohol, dimethylformamide, n-methyl-2-pyrrolidone, dichloroethylene, or chloroform.
  • steps 310 and 312 The times, weights, and ratios of the weights given above are examples for the purpose of illustration only and can be varied by one skilled in the art to obtain desired results.
  • the solvent can vary from about 1.9 liters-7.6 liters (0.5 gallon-2 gallons).
  • CNT can be varied from 0.5 grams-10 grams, in an example from 0.6 grams-5 grams, in another example from 0.8 grams-2 grams.
  • the order of steps 218 to 310-314 can be varied by one skilled in the art and/or steps 310-314 can be combined as necessary for convenience.
  • the brass and copper granules of steps 310-312 can be added to the acetone in the blender at the same time.
  • the ABC25G-CNT powder can be optionally filtered after being dried.
  • the weights of brass and copper discussed above in connection with step 316 were chosen for effectiveness as well as convenience with the available equipment and can be varied depending on desired parameters as well as sizes of mixing containers.
  • the weight of each of brass and copper in step 316 can range from 6.8 kilograms-22.6 kilograms (15 pounds-50 pounds), in another example between about 9.1 kilograms-15.9 kilograms (20 pounds-35 pounds), and in another example between about 10 kilograms-13.6 kilograms (22 pounds-30 pounds).
  • the amount of the third example treated material namely, the ABC25- CNT powder can be varied when added to the ferrous and/or nonferrous metal(s). Accordingly, the foregoing examples including weights and/or ratio of weights and mixing times are not to be construed in a limiting sense but only as examples of forming the third example treated material and using the third example treated material to form the treated metal or alloy.
  • additives Before or during the melting of the ferrous and/or nonferrous metal(s) in the casting operation, other additives can be added, such as, in an example, metallic alloys, plastic, cloth, or any combination thereof.
  • the third example treated material enables the material being treated, for example, the ferrous and/or nonferrous metal(s), to achieve greater electrical and mechanical properties than said ferrous and/or nonferrous metal(s) would achieve without the third example treated material. It is also believed that one or more of the following properties of ferrous and/or nonferrous metal(s) mixed with the third example treated material are improved by use of the third example treated material in the manner discussed above: thermal conductance, electrical conductance, hardness, and resistance to microwaves.
  • the third example treated material and/or the ferrous and/or nonferrous metal(s) treated with the third example treated material can be part of a coating that can be applied in any suitable and/or desirable manner to other materials such as metal, plastic, cloth, etc. to form a coating on said other materials.
  • a mixture formed by mixing the third example treated material with copper (in the ratios discussed above) was molded into a small cup with a cover. This cup was partially filled with water and a live inchworm was placed therein. The cover was then placed on the filled cup which was then placed inside of a home-grade microwave next to a coffee mug filled with water. The microwave was operated for 3 minutes on full power. Both the mug and the cup were removed from the microwave whereupon the water in the mug was observed to be steaming but the water in the cup formed from the copper mixture was still cool to the touch and the inchworm was observed to be moving.
  • the cup was also used to test the effects on digital storage devices (thumb drives) to microwave radiation.
  • a thumb device partially loaded with files was placed in the cup and the lid placed thereon. After 3 minutes of exposure to microwaves in the home-grade microwave at full power, the thumb drive was removed from the cup and inserted into a computer port. The files were observed to still be readable.
  • the copper mixture formed from the third example treated material can be used for safe containment, transport, and storage of materials or elements that emit ionizing radiation, such as isotypes used for nuclear medicine, nuclear waste, and the like. This copper alloy blocks radiation and is an excellent heat sink, features that will contain radiation but avoid heat buildup.
  • This copper alloy can replace all or a part of thick steel used in current containers. Hospital and clinic treatment rooms can benefit from containers made with the copper alloy for containment of administered isotopes in a variety of tests. Moreover, spent nuclear reactor fuel, which is highly radioactive and often hot, can be contained.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)

Abstract

L'invention concerne un procédé de traitement dans lequel un solvant pour les matériaux, des grains de laiton, des grains de cuivre et des nanotubes de carbone sont mélangés, en l'absence d'argent, de pyrite de fer et de graphène, pour former un premier mélange. Le premier mélange est ensuite ajouté à un second mélange de grains de laiton et de cuivre. Les premier et second mélanges sont mélangés jusqu'à ce que tous les grains du second mélange de laiton et de cuivre soient uniformément saturés avec le premier mélange, après quoi le second mélange est séché pour former un matériau traité. Le matériau traité peut être mélangé avec un ou plusieurs métaux ferreux et/ou non ferreux à haute température jusqu'à sa fusion pour former un alliage métallique. L'alliage métallique fondu peut être versé dans un moule et amené à refroidir et durcir. L'alliage métallique refroidi et durci peut être mis sous une forme finie par l'intermédiaire d'un étirage dans une filière ; d'une coulée continue ; ou d'un laminage.
PCT/US2016/036413 2009-11-06 2016-06-08 Procédé de fabrication d'un fil électrique à haut rendement WO2016200913A1 (fr)

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US15/069,172 US20160265087A1 (en) 2009-11-06 2016-03-14 Metal or Alloy with Improved Physical and Electrical Properties
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CN106191507A (zh) * 2016-08-23 2016-12-07 江西理工大学 一种制备石墨烯增强铜基复合材料的方法
CN107812880A (zh) * 2017-11-01 2018-03-20 内蒙古汇豪镁业有限公司 一种将石墨烯加入镁及镁基合金铸造模具中的方法
CN108405650A (zh) * 2018-03-05 2018-08-17 清远楚江铜业有限公司 一种艾灸盒用铜板带加工工艺
CN108588529A (zh) * 2018-04-13 2018-09-28 上海交通大学 石墨烯修饰界面的高导热金属基复合材料及其制备方法
CN109694967A (zh) * 2019-01-14 2019-04-30 广西大学 一种铜/石墨烯复合材料的制备方法
CN109825734A (zh) * 2019-04-01 2019-05-31 江西理工大学 协同增强铜基复合材料及其制备方法
CN110684910A (zh) * 2018-07-06 2020-01-14 慧隆科技股份有限公司 石墨烯金属复合材料制造方法
CN110819842A (zh) * 2019-10-25 2020-02-21 中国航发北京航空材料研究院 基于还原氧化石墨烯和铜复合材料的成型件制备方法
CN113215434A (zh) * 2021-04-30 2021-08-06 浙江利丰电器股份有限公司 一种换向器铜片用高导电银铜合金

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Publication number Priority date Publication date Assignee Title
CN106191507A (zh) * 2016-08-23 2016-12-07 江西理工大学 一种制备石墨烯增强铜基复合材料的方法
CN106191507B (zh) * 2016-08-23 2017-10-24 江西理工大学 一种制备石墨烯增强铜基复合材料的方法
CN107812880A (zh) * 2017-11-01 2018-03-20 内蒙古汇豪镁业有限公司 一种将石墨烯加入镁及镁基合金铸造模具中的方法
CN108405650A (zh) * 2018-03-05 2018-08-17 清远楚江铜业有限公司 一种艾灸盒用铜板带加工工艺
CN108405650B (zh) * 2018-03-05 2020-05-19 清远楚江铜业有限公司 一种艾灸盒用铜板带加工工艺
CN108588529A (zh) * 2018-04-13 2018-09-28 上海交通大学 石墨烯修饰界面的高导热金属基复合材料及其制备方法
CN110684910A (zh) * 2018-07-06 2020-01-14 慧隆科技股份有限公司 石墨烯金属复合材料制造方法
CN109694967A (zh) * 2019-01-14 2019-04-30 广西大学 一种铜/石墨烯复合材料的制备方法
CN109694967B (zh) * 2019-01-14 2020-12-25 广西大学 一种铜/石墨烯复合材料的制备方法
CN109825734A (zh) * 2019-04-01 2019-05-31 江西理工大学 协同增强铜基复合材料及其制备方法
CN110819842A (zh) * 2019-10-25 2020-02-21 中国航发北京航空材料研究院 基于还原氧化石墨烯和铜复合材料的成型件制备方法
CN113215434A (zh) * 2021-04-30 2021-08-06 浙江利丰电器股份有限公司 一种换向器铜片用高导电银铜合金

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