Method for manufacturing metal foam

Patent metadata

Field	Value
Publication number	US-11298745-B2
Application number	US-201716089864-A
Country	US
Kind code	B2
Filing date	Apr 3, 2017
Priority date	Apr 1, 2016
Publication date	Apr 12, 2022
Grant date	Apr 12, 2022

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:
sintering a green structure,
wherein the green structure consists of a metal component and a salt, and optionally a binder and/or solvent,
wherein the metal component comprises a conductive metal in an amount of 55% by weight or more,
wherein the metal component is in a form of a powder, and
wherein the sintering of the green structure consists of applying an electromagnetic field to said structure so as to generate heat from the conductive metal in the metal component,
wherein the green structure is in a form of a film or a sheet having a thickness of 1,000 μm or less,
wherein the conductive metal is nickel, iron or cobalt,
wherein the conductive metal has an average particle diameter in a range of 10 μm to 100 μm,
wherein the salt is NaCl, KCl, K 2 CO 3 , KOH, NaOH, CsCl, CaCl 2 , MgBr 2 , MgCl 2 , Na 2 SiO 3 , Na 2 CO 3 , NaHCO 3 , NH 4 Br or NH 4 Cl,
wherein the salt has a particle diameter in a range of 30 μm to 250 μm,
wherein the electromagnetic field is formed by applying a current at a frequency in a range of 100 kHz to 1,000 kHz, and
wherein the green structure is formed by coating a mixture of the metal component and the salt on a substrate.

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 green structure comprises, on the basis of weight, 30% by weight or more of the conductive metal.

4. The method for manufacturing a metal foam according to claim 1 , wherein the green structure comprises 10 to 1,000 parts by weight of the salt, relative to 100 parts by weight of the metal component.

5. 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.

6. 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 900 kHz.

7. 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.

8. The method for manufacturing a metal foam according to claim 1 , further comprising removing the salt after sintering.

9. The method of claim 1 , further comprising forming the metal foam having uniformly formed pores.

10. The method of claim 9 , wherein the metal foam has a porosity in a range of about 40% to 99%.

Assignees

• Lg Chemical Ltd

Inventors

• Yoo Dong Woo
• Lee Jin Kyu

Classifications

• 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

• B22F3/11 Primary

  Making porous workpieces or articles · CPC title

• B22F2003/1053

  by induction · CPC title

• B22F3/1134 Primary

  Inorganic fillers (carbonaceous or paper filler B22F3/1121) · CPC title

• B22F3/1146

  After-treatment maintaining the porosity (B22F3/114 takes precedence) · CPC title