Method for manufacturing metal foam

Patent metadata

Field	Value
Publication number	US-11980942-B2
Application number	US-201716348762-A
Country	US
Kind code	B2
Filing date	Nov 29, 2017
Priority date	Nov 30, 2016
Publication date	May 14, 2024
Grant date	May 14, 2024

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 in a very short time a metal foam comprising uniformly formed pores and having excellent mechanical properties as well as the desired porosity, and a metal foam produced by the above method. 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, in a short time, and such a metal foam.

First claim

What is claimed is:

1. A method for manufacturing a metal foam, the method comprising:
applying an electromagnetic field to a green structure comprising a polymer foam, said polymer foam comprising a surface with a layer of a metal component, and said metal component comprising a conductive metal having a relative magnetic permeability of 90 or more; and
sintering the metal component with heat generated by induction heating of the conductive metal, wherein the sintering of the green structure is carried out only by the induction heating, wherein the polymer foam decomposes during said sintering,
to thereby manufacture the metal foam,
wherein the green structure is formed by plating the metal component on the polymer foam,
wherein the plating is an electrolytic plating,
wherein the electromagnetic field is formed by applying a current in a range of 250 A to 400 A and at a frequency in a range of 250 kHz to 400 kHz,
wherein the electrolytic plating is carried out by forming a titanium film on the polymer foam, and then electrolytically plating the conductive metal on the polymer foam, and
wherein the electromagnetic field is applied for a time of about 1 minute to 30 minutes.

2. The method for manufacturing a metal foam according to claim 1 , wherein the polymer foam is a polyurethane foam, an acrylic foam, a polystyrene foam, a polyolefin foam, a polycarbonate foam, or a polyvinyl chloride foam.

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

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

5. The method for manufacturing a metal foam according to claim 1 , wherein the metal component comprises 30 wt % or more of the conductive metal.

6. The method for manufacturing a metal foam according to claim 1 , wherein the induction heating comprises a first induction heating, and a second induction heating performed under conditions different from the first induction heating.

7. The method for manufacturing a metal foam according to claim 1 , wherein the polymer foam is in the form of a film or sheet, and the metal foam produced is in the form of a film or sheet.

8. The method for manufacturing a metal foam according to claim 1 , wherein the metal foam is in the form of a film or sheet having a thickness of 2,000 μm or less.

9. The method for manufacturing a metal foam according to claim 1 , wherein the conductive metal is nickel.

10. The method for manufacturing a metal foam according to claim 1 , wherein the porosity of the metal foam is 93% or more.

Assignees

• Lg Chemical Ltd

Inventors

• Yoo Dong Woo
• Lee Jin Kyu

Classifications

• B22F3/1137 Primary

  by coating porous removable preforms · CPC title

• B22F3/105 Primary

  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

• B22F5/006

  of flat products, e.g. sheets (B22F3/1103 takes precedence; by using pressure rollers only see B22F3/18) · CPC title

• B22F2003/1053

  by induction · CPC title

• B22F7/002 Primary

  of porous nature · CPC title