Foam skeleton reinforced composite, preparation method therefor, and application thereof

Patent metadata

Field	Value
Publication number	US-2019112445-A1
Application number	US-201716086608-A
Country	US
Kind code	A1
Filing date	Feb 22, 2017
Priority date	Mar 21, 2016
Publication date	Apr 18, 2019
Grant date	—

Abstract

A foamed skeleton reinforced composite, comprising a foamed skeleton and a matrix material. The foamed skeleton is selected from at least one of a metal foamed skeleton, an inorganic non-metal foamed skeleton, and an organic foamed skeleton. The matrix material is selected from a metal or a polymer.

First claim

1 - 15 . (canceled)

16 . A composite material reinforced by a foamed skeleton, comprising:
a foamed skeleton having pores, wherein a material of the foamed skeleton is a metal material, an inorganic non-metallic material comprising a ceramic material and carbon, or an organic non-metallic material; and a matrix, wherein a material of the matrix is a metal material or a polymer material.

17 . The composite material of claim 16 ,
wherein the metal material of the matrix is selected from a group consisting of Al, Cu, Mg, Ag, Ti, Co, Ni, W, Mo, Ta, Nb, and any alloys thereof; and wherein the polymer material of the matrix is a paraffin, a thermoplastic polymer or a thermosetting polymer; the thermoplastic polymer is polyethylene, polypropylene, polystyrene, polyvinyl chloride, polytetrafluoroethylene, nylon, polycarbonate, polymethyl methacrylate, ethylene glycol, polyterephthalic acid, polyformaldehyde, polyamide, or polysulfone; the thermosetting polymer is an epoxy resin, a phenolic resin, a urea-formaldehyde resin, an amino resin, a melamine resin, an unsaturated polyester resin, a silicone rubber, a foamed polystyrene, or a polyurethane.

18 . The composite material of claim 16 ,
wherein the metal material of the foamed skeleton is Ni, Cu, Ti, Co, W, Mo, Cr, Fe Ni or Al; wherein the inorganic non-metallic material of the foamed skeleton is carbon, Al 2 O 3 , ZrO 2 , SiC, Si 3 N 4 , BN, B 4 C, AlN, WC or Cr 7 C 3 ; and wherein the organic non-metallic material of the foamed skeleton is sponge, polyurethane (PUR), polystyrene (PS), polyvinyl chloride (PVC), polyethylene (PE) or phenolic resin (PF).

19 . The composite material of claim 16 , further comprising
a reinforcing layer on the foamed skeleton, wherein the reinforcing layer is a diamond film, a graphene film, a carbon nanotube film, a diamond/graphene film, a diamond/carbon nanotube film, a graphene/carbon nanotubes film, a carbon nanotube/graphene film, a carbon nanotube/graphene film, a diamond/graphene/carbon nanotube film, or a diamond/carbon nanotube/graphene film.

20 . The composite material of claim 19 , wherein
the diamond/graphene film is formed by growing graphene on a diamond film in a direction perpendicular to the diamond film to form graphene walls, or in a direction parallel to the diamond film to form a graphene film; the diamond/carbon nanotube film is formed by catalytically growing carbon nanotubes on a diamond film, a nitrogen-doped diamond film, or a boron-doped diamond film in a direction perpendicular to the diamond film, the nitrogen-doped diamond film, or the boron-doped diamond film to form a carbon nanotube forest; the graphene/carbon nanotube film is formed by catalytically growing carbon nanotubes on a graphene film, and the carbon nanotubes ae perpendicular to the graphene film to form a carbon nanotube forest; the carbon nanotube/graphene film is formed by catalytic growing graphene on the surface of carbon nanotube, and the graphene is perpendicular or parallel to the surface of the carbon nanotubes; the diamond/graphene/carbon nanotube film is formed by growing graphene on a diamond film and then catalytically growing carbon nanotubes on the graphene film, the graphene is parallel to the diamond film to form a graphene film, and the carbon nanotubes are perpendicular to the diamond film to form a carbon nanotube forest; the diamond/carbon nanotubes/graphene film is formed by catalytically growing carbon nanotubes on the diamond film, and then growing graphene walls on the surface of carbon nanotubes.

21 . The composite material of claim 19 , further comprising an intermediate transition layer between the foamed skeleton and the reinforcing layer, wherein a material of the intermediate transition layer is Nb, Ti, Ni, W, Mo, Cr, Ta, Pt, Ag, Si, or any combinations thereof.

22 . The composite material of claim 19 , further comprising a modifying layer on the reinforcing layer when a material of the matrix is the metal material, wherein a material of the modifying layer is a metal selected from W, Mo, Cr, Ti, Ni, Cu, Al and Pt, a metal carbide selected from tungsten carbide, molybdenum carbide, chromium carbide and titanium carbide, or an alloy selected from a tungsten alloy, a molybdenum alloy, a chromium alloy, a titanium alloy, a nickel alloy, a copper alloy, an aluminum alloy and a platinum alloy.

23 . The composite material of claim 16 , wherein the pores of the foamed skeleton have a diameter of 0.01-10 mm, a porosity of the foamed skeleton is 40-99%, and the foamed skeleton is a planar structure or a three dimensional structure.

24 . The composite material of claim 16 , further comprising reinforcing particles distributed in the pores of the foamed skeleton, wherein the reinforcing particles are highly thermal conductivity particles, super-hard and wear-resistant particles, conductive particles, or any combinations thereof, and
wherein the highly thermal conductivity particles are selected from at least one of diamond powders, graphene, carbon nanotubes, graphene coated diamond microspheres, carbon nanotube coated diamond microspheres, and carbon nanotube coated graphene, the super-hard and wear-resistant particles are selected from at least one of the diamond powders, SiC, TiC, TiN, AlN, Si 3 N 4 , Al 2 O 3 , BN, WC, MoC and Cr 7 C 3 , and the conductive particles are selected from at least one of graphite, carbon nanotubes, and graphene.

25 . The composite material of claim 24 , wherein
the volume fraction of the matrix is 10-90%, the volume fraction of the foamed skeleton is 5-80%, and the volume fraction of the reinforcing particles is 0-30%.

26 . The composite material of claim 25 , wherein the foamed skeleton has a three-dimensional bulk structure to reinforce the matrix in a single-body way, or a sheet like or strip-like structure arranged in parallel to reinforce the matrix in a multi-body way.

27 . A method of preparing a composite material reinforced by a foamed skeleton, the method comprising:
cleaning a foamed skeleton; depositing an intermediate transition layer on the foamed skeleton by electroplating, electroless plating, evaporation, magnetron sputtering, chemical vapor deposition (CVD), or physical vapor deposition (PVD), wherein the intermediate transition layer is a layer of Nb, Ni, Cu, W, Mo, Ti, Ag, Cr, or any combinations thereof; depositing a reinforcing layer on the intermediate transition layer, wherein the reinforcing layer is a diamond film, a graphene film, a carbon nanotube film, a diamond/graphene film, a diamond/carbon nanotubes film, a graphene/carbon nanotubes film, a carbon nanotube/graphene film, a carbon nanotube/graphene film, a diamond/graphene/carbon nanotube film or a diamond/carbon nanotube/graphene film; and compounding the foamed skeleton with a matrix.

28 . The method of claim 27 , wherein when the reinforcing layer is the diamond film, the graphene film, or the carbon nanotube film, the deposition method of the reinforcing layer comprises:
growing a diamond seed layer on the intermediate transition layer, the growing method comprises:
immersing the foamed skeleton covered by the intermediate transition layer in a suspension solution of nanocrystalline and/or microcrystalline diamond particles; and
planting the nanocrystalline and/or microcrystalline diamond particles onto the foamed skeleton by ultrasonic oscillation, spray atomization, or electrostatic adsorption; and
depositing the diamond film, the graphene film, or the carbon nanotube film on the surface of the intermediate transition layer or the diamond particles by CVD.

29 . Th

Assignees

• Univ Central South

Inventors

• Zhou Kezhao
• Wei Qiuping
• Ma Li
• Zhang Long
• Yu Zhiming

Classifications

• C23C16/26

  Deposition of carbon only · CPC title

• C23C16/50

  using electric discharges {(generation and control of plasma in discharge tubes for surface treatment H01J37/32, H01J37/34)} · CPC title

• C23C16/045

  Coating cavities or hollow spaces, e.g. interior of tubes; Infiltration of porous substrates · CPC title

• C23C16/271

  using hot filaments · CPC title

• B22F2999/00

  Aspects linked to processes or compositions used in powder metallurgy · CPC title