Method for manufacturing metal foam

Patent metadata

Field	Value
Publication number	US-11141786-B2
Application number	US-201716089191-A
Country	US
Kind code	B2
Filing date	Apr 3, 2017
Priority date	Apr 1, 2016
Publication date	Oct 12, 2021
Grant date	Oct 12, 2021

Abstract

The present application provides a method for manufacturing a metal foam. The present application can provide a method for manufacturing a metal foam, which is capable of forming a metal foam comprising uniformly formed pores and having excellent mechanical properties as well as the desired porosity, and a metal foam having the above characteristics. In addition, the present application can provide a method capable of forming a metal foam in which the above-mentioned physical properties are ensured, while being in the form of a thin film or sheet, within a fast process time, and such a metal foam.

First claim

The invention claimed is:

1. A method for manufacturing a metal foam comprising:
preparing a structure using a slurry,
applying an electromagnetic field to the structure,
wherein the slurry consists of a metal component, an organic binder, and optionally solvent and/or binder,
wherein the metal component comprises a conductive metal having a relative magnetic permeability of 90 or more,
wherein the metal component comprises, on the basis of weight, 30% by weight or more of the conductive metal, and
wherein the metal component to which the electromagnetic field is applied is in the form of powder.

2. The method for manufacturing a metal foam according to claim 1 , wherein the conductive metal has a conductivity at 20° C. of 8 MS/m or more.

3. The method for manufacturing a metal foam according to claim 1 , wherein the conductive metal is nickel, iron or cobalt.

4. The method for manufacturing a metal foam according to claim 1 , wherein the conductive metal has an average particle diameter in a range of 5 μm to 100 μm.

5. The method for manufacturing a metal foam according to claim 1 , wherein the organic binder is alkyl cellulose, polyalkylene carbonate, polyvinyl alcohol, polyalkylene oxide or polyvinyl acetate.

6. The method for manufacturing a metal foam according to claim 1 , wherein the slurry comprises 10 to 400 parts by weight of the organic binder, relative to 100 parts by weight of the metal component.

7. The method for manufacturing a metal foam according to claim 1 , wherein the structure is in a film or sheet shape.

8. The method for manufacturing a metal foam according to claim 7 , wherein the film or sheet shape has a thickness of 5,000 μm or less.

9. The method for manufacturing a metal foam according to claim 1 , wherein the electromagnetic field is formed by applying a current in a range of 100 A to 1,000 A.

10. The method for manufacturing a metal foam according to claim 1 , wherein the electromagnetic field is formed by applying a current at a frequency in a range of 100 kHz to 1,000 kHz.

11. The method for manufacturing a metal foam according to claim 1 , wherein the electromagnetic field is applied for a time in a range of 1 minute to 10 hours.

Assignees

• Lg Chemical Ltd

Inventors

• Yoo Dong Woo
• Lee Jin Kyu

Classifications

• B22F2003/1053

  by induction · CPC title

• B22F3/11 Primary

  Making porous workpieces or articles · CPC title

• B22F3/105

  by using electric current {other than for infrared radiant energy}, laser radiation or plasma (B22F3/11 takes precedence){; by ultrasonic bonding (B22F3/115 takes precedence)} · CPC title

• B22F2003/1131

  Foaming in a liquid suspension and decomposition · CPC title

• B22F2202/05

  Use of magnetic field · CPC title