Flexible metal-foam mesh hybrid material

Abstract

Metal-foam mesh structures are used in a variety of applications where flexible mesh structures are utilized, such as steam chamber wicks and various diaphragms and energy electrodes. The new metal-foam mesh hybrid material has a three-dimensionally connected microporous structure and has improved mechanical properties, including good strength, ductility, flexibility, and other properties.

Description

[Technical Field]

[0001] explanation CROSS-REFERENCE TO RELATED APPLICATIONS This patent application claims the benefit of U.S. Patent Application No. 63 / 484,452, filed February 10, 2023, which is incorporated by reference along with all other references cited in this application.

[0002] Background of the Invention The present invention relates to materials, and more particularly to flexible metal foam mesh structures for a variety of applications and techniques for making and using such metal foam mesh structures. Summary of the Invention [Problem to be solved by the invention]

[0003] There is a need for improved materials, particularly metal foam mesh structures. [Means for solving the problem]

[0004] Summary of the Invention Metal foam mesh structures are used in a variety of applications where mesh structures are utilized, such as steam chamber wicks and various diaphragms. Metal foam mesh structures are used in a variety of applications where flexible mesh structures are utilized, such as steam chamber wicks and various diaphragms and energy electrodes. The new metal foam mesh hybrid material has a three-dimensionally connected microporous structure and has improved mechanical properties, including good strength, ductility, flexibility, and other properties.

[0005] Some embodiments include: a method for making a flexible metal foam mesh hybrid material comprising a woven or nonwoven metal mesh and a metal foam comprising a three-dimensionally connected pore structure with a porosity ranging from about 60 percent to about 95 percent. Alternatively, instead of or in combination with the woven or nonwoven metal mesh, the starting material or substrate can include felt, natural or synthetic fibers, leather, knitted materials, textiles, jersey fabrics, flexible materials, or other materials.

[0006] The metal mesh may be a copper mesh in the form of a sheet having a thickness ranging from about 100 microns to about 500 microns, and has an open pore structure with rectangular or square pore shapes and pore sizes ranging from about 50 microns to about 1000 microns.

[0007] The manufacturing process for forming the copper foam mesh hybrid material can include a freeze casting method that includes a copper or copper oxide powder slurry that includes a binder, a dispersant, and water as a solvent, and immersing a mesh in the prepared slurry.

[0008] The metal mesh material can include at least one of copper, copper-tin alloy, copper-zinc alloy, copper-nickel alloy, copper-silicon alloy, copper-aluminum alloy, nickel, zinc, tin, gold, silver, iron, steel, aluminum, or titanium, or any combination thereof.

[0009] The metal foam material can include at least one of copper, copper-tin alloy, copper-zinc alloy, copper-nickel alloy, copper-silicon alloy, copper-aluminum alloy, nickel, zinc, tin, gold, silver, iron, steel, aluminum, or titanium, or a metal oxide material thereof, or any combination thereof.

[0010] The slurry can be coated onto a mesh and frozen at a temperature of about −80° C. (or about −60° C.) to about −5° C. Alternatively, the slurry can be coated onto a mesh and dried in an oven (e.g., a heating oven) at a temperature of about 40° C. to about 200° C. (without a freezing process). In yet further embodiments, a combination of freeze-drying and oven drying may be used.

[0011] Once the coated slurry is frozen, the frozen slurry and mesh structure are then sublimated in a freeze dryer for several hours to several tens of hours (e.g., 2, 3, 4, 5, 10, 15, 20, 25, 30, or 40 hours, at least 2 hours, at least 3 hours, or at least 4 hours). The reduction and sintering process can include reducing at a temperature of about 200°C to about 400°C for about 2 hours to about 5 hours (first sintering) and sintering at a temperature of about 600°C to 1000°C for about 2 hours to about 5 hours (second sintering).

[0012] In a further embodiment, a structure comprises a first layer or substrate comprising a metal mesh template and a second layer of metal foam formed on or bonded to a surface of the first layer, the metal foam comprising a three-dimensionally connected pore structure with a porosity ranging from about 60 percent to about 95 percent.

[0013] The metal mesh template can include a copper mesh having a thickness of about 100 microns to about 500 microns. The metal foam layer can include at least one of copper, copper alloy, nickel, iron, steel or iron alloy, or titanium. The metal foam layer can have a thickness of about 100 microns to about 500 microns. The metal mesh can have a mesh pore size range of about 50 mesh to 1000 mesh.

[0014] Other objects, features, and advantages of the present invention will become apparent from consideration of the following detailed description and the accompanying drawings, in which like reference characters represent like features throughout. [Brief explanation of the drawings]

[0015] [Figure 1] FIG. 1 shows a flow chart diagram illustrating the manufacturing sequence of a flexible copper foam mesh structure. [Figure 2] 1 illustrates a manufacturing process for forming a metal foam mesh hybrid structure on a metal mesh template using a slurry coating method. [Figure 3] An example of the final copper foam mesh structure is shown. DETAILED DESCRIPTION OF THE INVENTION

[0016] Detailed Description of the Invention FIG. 1 shows a flow chart diagram illustrating the detailed manufacturing sequence of the flexible copper foam mesh structure.

[0017] 2 shows a manufacturing process for forming a metal foam mesh structure on a metal mesh template using a slurry coating method. Techniques for creating a metal foam mesh structure can include:

[0018] 1. The slurry is used as the coating material. Mesh, such as commercially available woven or nonwoven mesh materials, felt, starting substrates, or starting materials, is utilized. The mesh can be metallic or nonmetallic. Mesh grades can range from about 10 to about 2000 mesh. After the slurry is frozen and / or dried, a sintering process is used to form a chemical bond between the metal mesh and the slurry.

[0019] 1a. A slurry is produced by mixing ceramic, metal, or polymer powder with a solution containing water, a solvent or chemical, a dispersant, and a binder.

[0020] 1b. The slurry can be coated onto a mesh and frozen at about -60°C to about 5°C, or -80°C to about -5°C, or simply dried in an oven at about 40°C to about 200°C without the freezing process.

[0021] 1c. In the previous step, when the coated slurry is frozen, the frozen slurry and mesh structure are sublimated in a freeze dryer for several hours to several tens of hours.

[0022] 1d. For sintering, the dried porous green body structure is sintered at a relatively high temperature for at least several hours. Sintering may include two sintering steps: a first sintering at a first temperature, followed by a first sintering at a second temperature, the first temperature being lower than the second temperature. The sintering temperature depends on the melting temperature of the metal. For example, in one embodiment, the applied sintering temperature (e.g., the second sintering temperature in a two-step sintering process) is approximately ⅔ of the melting point of the material.

[0023] 2. Coating thickness can be controlled using a blade or the like on a mesh substrate.

[0024] 3. Coating can also be done by dipping the mesh into the prepared slurry.

[0025] 4. Copper (Cu), copper alloys, nickel (Ni), steel (iron alloys), titanium (Ti), iron (Fe), and other metal foams (or conductors) can all be applied.

[0026] Figure 3 shows an example of a copper foam mesh structure before (top image) and after (bottom image) a copper foam coating is applied, demonstrating a high porosity of approximately 90 percent and considerable bendability (right image).

[0027] 5. Applications include steam chamber wicks and various diaphragms.

[0028] U.S. Patent Application Nos. 62 / 194,564, filed July 20, 2015, 15 / 215,519, filed July 20, 2016, 62 / 194,677, filed July 20, 2015, 15 / 215,541, filed July 20, 2016, 62 / 641,223, filed March 9, 2018, PCT / US2019 / 021704, filed March 11, 2019, 61 / 700,793, filed July 19, 2018, and PCT / US2019 / 042686, filed July 19, 2019, are incorporated by reference. These applications describe techniques for producing metal foams. These techniques can be used to fabricate metal foam mesh structures, in whole or in part.

[0029] The patent describes several example embodiments with specific dimensions, measurements, temperatures, and values. These are not intended to be exhaustive or to limit the invention to the precise forms described. Numerical values, percentages, times, and temperatures are approximate. These values ​​may vary due to, for example, measurement or manufacturing variations or tolerances or other factors. For example, depending on the tightness of manufacturing and measurement tolerances, temperature and time values ​​may vary by plus or minus 2.5 percent, plus or minus 5 percent, plus or minus 7.5 percent, plus or minus 10 percent, plus or minus 15 percent, plus or minus 20 percent, or plus or minus 25 percent.

[0030] Furthermore, the values ​​are for particular embodiments, and other embodiments may have different values, such as a particular value being larger for a larger-sized process or product, or smaller for a smaller-sized product. A device, apparatus, or process may be made proportionally larger or smaller by proportionally adjusting the relative measurements (e.g., maintaining the same or approximately the same ratio between different measurements). In various embodiments, the values ​​may be the same as the given value, approximately the same as the given value, at least or greater than the given value, or less than or equal to the given value, or any combination thereof.

[0031] Several techniques or flows are described in Figure 1. The flows may have additional steps (not necessarily described in this patent), different steps replacing some of the steps presented, fewer steps or a subset of the steps presented, or steps in a different order than those presented, or any combination thereof. Additionally, the steps in other embodiments may not be exactly the same as the steps presented and may be modified or altered as appropriate for a particular application or based on the circumstances.

[0032] FIG. 2 illustrates the fabrication process of forming a metal foam mesh hybrid structure on a metal mesh template using a slurry coating method.

[0033] Figure 3 shows an example of the final copper foam mesh structure.

[0034] 1, the first step involves preparing a copper mesh, for example, 200 mesh. For example, the mesh pore size range can be from about 50 to about 1000 mesh.

[0035] The second step involves preparing a copper powder slurry with a solids content of about 60 weight percent by mixing with a solution of water and binder. For example, the solids content can range from about 40 weight percent to about 80 weight percent.

[0036] The third step involves coating the resulting slurry onto a mesh to a thickness of about 100 microns. For example, the thickness of the mesh may range from about 100 microns to about 500 microns. Alternatively, the thickness of the mesh may range from about 50 microns to about 500 microns.

[0037] Referring to FIG. 2, use a coating blade to uniformly spread and thin the metal slurry onto the metal mesh template to a desired thickness (e.g., about 100 microns to about 500 microns, about 50, 100, 150, 200, 250, 300, 350, 400, 450, 500, or 550 microns).

[0038] The fourth step involves freezing the slurry mesh structure at about −40° C. For example, the temperature used to freeze the slurry mesh structure can range from about −60° C. to about −5° C., or from about −80° C. to about −5° C. Additionally, the temperature used to freeze the slurry mesh structure can be below about 0° C.

[0039] See Figure 2. A metal mesh template of the desired thickness (thinner for coating blades) is freeze-dried or heat-dried.

[0040] The fifth step involves sublimation in a freeze dryer for about 10 hours. For example, the sublimation time may range from about 8 hours to about 12 hours. The time may also depend on the temperature and pressure used.

[0041] The sixth step involves (first) sintering the dried structure at about 300°C for about 2 hours, followed by (second) sintering at about 680°C for about 3 hours. For example, the first sintering can be in the range of about 200°C to about 400°C for about 2 hours to about 5 hours. The second sintering can be in the range of about 600°C to about 800°C for about 2 hours to about 5 hours. The first sintering can be referred to as a debinding and reduction process.

[0042] The seventh step involves obtaining a copper foam mesh material. See Figure 3, which shows several examples of the resulting copper foam mesh material at different magnifications. The copper foam mesh material is highly flexible and can be wrapped or folded around materials such as pipes or other curved structures.

[0043] This description of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form described, and many modifications and variations are possible in light of the above teachings. The embodiments were chosen and described to best explain the principles of the invention and its practical applications. This description will enable those skilled in the art to best utilize and practice the invention in various embodiments, with various modifications suited to particular applications. The scope of the invention is defined by the following claims.

Claims

1. forming a flexible metal foam mesh hybrid material comprising a woven or nonwoven metal mesh, felt, or any starting substrate, and a metal foam comprising a three-dimensionally connected pore structure with a porosity ranging from about 60 percent to about 95 percent; A method comprising:

2. The method of claim 1, wherein the metal mesh is a copper mesh in the form of a sheet having a thickness ranging from about 100 microns to about 500 microns.

3. 10. The method of claim 1, wherein the metal mesh has an open pore structure with rectangular or square pore shapes, and the pore diameters range from about 50 microns to about 1000 microns.

4. Freeze casting using a copper or copper oxide powder slurry containing a binder, a dispersant, and water as a solvent The method of claim 1 , comprising:

5. dipping the mesh into the copper or copper oxide powder slurry; The method of claim 1 , comprising:

6. 10. The method of claim 1, wherein the metal mesh material comprises at least one of copper, copper-tin alloy, copper-zinc alloy, copper-nickel alloy, copper-silicon alloy, copper-aluminum alloy, nickel, zinc, tin, gold, silver, iron, steel, aluminum, or titanium, or a combination.

7. 10. The method of claim 1, wherein the metal foam material comprises at least one of copper, copper-tin alloy, copper-zinc alloy, copper-nickel alloy, copper-silicon alloy, copper-aluminum alloy, nickel, zinc, tin, gold, silver, iron, steel, aluminum, or titanium, or a metal oxide material thereof, or a combination thereof.

8. 5. The method of claim 4, wherein the slurry is coated onto a mesh and frozen at a temperature of about -80°C to about -5°C.

9. 5. The method of claim 4, wherein the slurry is coated onto a mesh and dried in an oven at a temperature of about 40° C. to about 200° C. without the freezing process.

10. Sublimating the frozen slurry and mesh structure in a freeze dryer for at least 2 hours. The method of claim 8, comprising:

11. preparing a copper or copper oxide powder slurry containing a binder, a dispersant, and water as a solvent; coating the metal mesh with the copper or copper oxide powder slurry; reducing and sintering, reducing at a temperature of about 200°C to about 400°C for about 2 hours to about 5 hours; sintering at a temperature of about 600°C to 1000°C for about 2 hours to about 5 hours; reducing and sintering the The method of claim 1 , comprising:

12. a first layer comprising a metal mesh template; a second layer of metal foam bonded to a surface of the first layer, the metal foam comprising a three-dimensionally connected pore structure having a porosity ranging from about 60 percent to about 95 percent; and A structure comprising:

13. The structure wherein the metal mesh template comprises a copper mesh having a thickness of about 100 microns to about 500 microns.

14. 13. The structure of claim 12, wherein the metal foam layer comprises at least one of copper, a copper alloy, nickel, iron, steel or an iron alloy, or titanium.

15. 13. The structure of claim 12, wherein the metal foam layer has a thickness of about 100 microns to about 500 microns.

16. 13. The structure of claim 12, wherein the metal mesh has a mesh pore range of about 50 mesh to 1000 mesh.

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